Volkswagen Golf Service & Repair Manual: Removing and installing alternator, vehicles with TDI engine

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

Special tools and workshop equipment required

Torque wrench -V.A.G 1331-

Removing and installing alternator, vehicles with TDI engine

Torque wrench -V.A.G 1783-

Removing

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

–	Remove poly V-belt → Rep. gr.13.

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

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, vehicles with TDI engine

–	Remove bolts -arrows-.

Note

If alternator -C--1- 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--1- from bracket with electrical wiring still connected.

–	Disconnect electrical connector -5-.

–	Pry off cap -4-.

–	Unscrew nut and remove terminal 30/B+ -3-.

–	Unscrew nut -6- and pull off clamp -2-.

–	Remove alternator -C--1- 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, vehicles with TDI engine

Removing and installing alternator, vehicles with 2.0 l TSI engine

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

Removing and installing alternator, GTD

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

Other materials:

Removing and installing lower suspension link, vehicle with manual gearbox or dual clutch gearbox 0CW
Special tools and workshop equipment required Torque wrench -V.A.G 1332- Removing – Loosen wheel bolts. – ...

Tyre pressure
Fig. 201 On the inside of the tank flap: tyre inflation pressure label First read and observe the introductory information and safety warnings The correct tyre pressure for factory-fitted tyres is shown on a sticker and applies to all-season, summer and winter tyres. The sticker is l ...

Switch and sender in refrigerant circuit and related connections
Note See vehicle-specific refrigerant circuit for switching pressures, removing and fitting switches, together with switch arrangement and versions. → Rep. gr.87 ...