VW Golf manuals

Volkswagen Golf Service & Repair Manual: 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-
–  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
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-.
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.
Install in the reverse order of removal, observing the following:
–  To facilitate positioning of alternator -C-, slide bushes of alternator mounting slightly towards back.
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:

Product characteristics
Refrigerants used in car air conditioning systems belong to the new generation of refrigerants, the chlorine-free, partially-fluoridated hydrocarbons (H-CFC, R134a). In regard to their physical behaviour, they are refrigerants which can ...

Safety regulations for crash sensors (pressure sensors) for front side airbags
The side airbag crash sensors respond to changes in pressure and must therefore be treated with particular caution. Observe the following:   The correct installation position is vitally important: only install in the specified ...

Repairs to CAN bus wiring
  An unshielded two-wire line -1- and -2- with a cross section of 0.35 mm2 or 0.5 mm2 is used for CAN bus wiring. The colour codes of the CAN bus wiring can be gleaned from the following table:   ...

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