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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 model designation on radiator grille
  Note The description applies for all emblems. Here the “GTI” emblem is shown as an example.     Removing –  Removing radiator grille → Chapter –  ...

Conducting a road test before balancing wheels
If a customer brings a vehicle to the workshop complaining about “vibration”, a road test is essential prior to balancing the wheels. This will give you information about the nature of the vibration. ...

Seam seals, body of CNG-powered vehicles
  Note Seam seals made during repair work must be identical in appearance and thickness to the original seam seals. To avoid damage or faulty operation, brush seam seals smooth near attachments which must be attached. ...

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