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:

Removing and installing fuel pressure sender -G247-
Special tools and workshop equipment required Assembly tool -T10118- Socket, 27 mm -T40218- or commercially available 27 mm ...

Fastening rings
Fig. 99 In the luggage compartment: fastening rings First read and observe the introductory information and safety warnings You will find fastening rings at the front and rear of the luggage compartment which can be used to secure luggage (arrow). Some fastening rings have to be fold ...

Notes concerning odours in air conditioned vehicles
If the evaporator emits unpleasant odours, clean the evaporator. Volkswagen has tested and approved the ultrasound A/C cleaner -VAS 6189A- as well as the suction feed spray-gun -V.A.G 1538- with the appropriate spray probe. ...