Volkswagen Golf Service & Repair Manual: Removing and installing alternator, GTD

Volkswagen Golf Service & Repair Manual / Electrical system / Starter- current supply- CC / Alternator / Removing and installing alternator, GTD

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Removing and installing alternator, GTD

Torque wrench -V.A.G 1783-

Removing

–	With ignition switched off, disconnect earth cable from battery -A- → Chapter.

–	Remove tensioner for poly V-belt → Rep. gr.13.

–	Remove front part of right wheel housing liner → Rep. gr.66.

–	Remove radiator cowl → Rep. gr.19.

–	Drain off coolant → Rep. gr.19.

–	Remove coolant hose from radiator → Rep. gr.19.

Vehicles with auxiliary heater

–	Remove auxiliary heater exhaust pipe → Rep. gr.82.

Vehicles with air conditioner

Caution

Risk of damage to air conditioner compressor, refrigerant lines and refrigerant hoses:

Make sure refrigerant lines and hoses are not excessively stretched, kinked or bent.

–	Remove air conditioner compressor from bracket → Heating, air conditioning system; Rep. gr.87.

–	Secure air conditioner compressor to lock carrier so that refrigerant lines are not under tension.

Continued for all vehicles

Removing and installing alternator, GTD

–	Remove bolts -1-.

Note

If alternator -C--2- is stuck in its bracket, screw bolts in again except for the last 2 turns.

Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.

–	Remove alternator -C--2- from bracket with electrical wiring still connected.

–	Disconnect electrical connector -3-.

–	Pry off cap -4-.

–	Unscrew nut and remove terminal 30/B+ -5-.

–	Unscrew nut -6- and pull off clamp -7-.

–	Remove alternator -C--2- downwards to the right.

Installing

Install in the reverse order of removal, observing the following:

–	To facilitate positioning of alternator -C-, slide bushes of alternator mounting slightly towards back.

Note

Ensure that bushes of alternator mounting slide freely and are not to tight (loosen, if necessary); otherwise clamping force of sliding bushes is too low even if specified torque is applied.

–	Reconnect battery -A- → Chapter.

–	Always start engine and check belt running after completing work.

Specified torques

→ Chapter „Assembly overview - alternator“

Removing and installing alternator, GTD

Checking alternator

Checking alternator -C- → Vehicle diagnostic tester.

Removing and installing alternator, vehicles with TDI engine

Special tools and workshop equipment required Torque wrench -V.A.G 1331- ...

Removing and installing poly V-belt pulley without freewheel

Special tools and workshop equipment required Socket -3310- ...

Other materials:

Adjusting camber at front wheels
Special tools and workshop equipment required Torque wrench -V.A.G 1332- Note Camber correction is necessary only after body repairs. Camber cannot be ad ...

Repairing smooth pipe
Smooth pipe with a diameter or 5x1 mm or 6x1 mm can be repaired with EPDM hose. – Cut damaged section at right angles out of smooth pipe which is to be repaired. – Select the appropr ...

2-pack HS Optimum clear coat
Designation: 2-pack HS Optimum clear coat -LZK 769 K02 A5- Issued 10.2012 Product description 2-pack HS Optimum clear coat is a VOC compliant (VOC content < 420 g/l), high ...