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

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