Removing and installing alternator, 1.6 l diesel engine — AUDI

🧭 Before you start

Fits: VW Caddy IV (SA, 2015–2020)

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• 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. — Release and disconnect connector (1).
• Unscrew the lower of the two bolts (1) by approx. 1 cm; the bracket on fuel filter has a slit in it for installation and removal.
• If the alternator is stuck in its bracket, screw in the bolts (arrows) again except for the last two turns.Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.
• Free off stiff sliding sleeves or bushes of the alternator mounting. Otherwise, the clamping force of the sliding bushes will be too low even though the specified torque is set.
• Always start engine and check belt running after completing work.

📋 Procedure

1. Disconnect earth wire from batteryA.
2. Move lock carrier to service position General body repairs, exterior50Lock carrier from 2011; Moving to service position and resetting.
3. Remove poly V-belt Power unit13Cylinder block, belt pulley end; Removing and installing poly V-belt.
4. ⚠ 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. — Release and disconnect connector (1).
5. Unscrew securing bolts of air conditioner compressor (arrows). [Note: The hoses of the air conditioner compressor can remain connected.Suspend the air conditioner compressor using a piece of wire at a suitable position until it is ready to be reinstalled.Ensure that the hoses are not stretched or kinked.]

6. Release and disconnect connector of DF cable (1).
7. Lever off deflector cap (2).
8. Undo nut (1) and detach the B+ wire under it from the connecting thread of the alternator.
9. Undo nuts (3) and remove cable retainer (2) from alternator.
10. Undo the two securing bolts (1) and the nuts (2) of the fuel filter (3) and place fuel filter to one side. The fuel hoses can then remain connected. [Note: Unscrew the lower of the two bolts (1) by approx. 1 cm; the bracket on fuel filter has a slit in it for installation and removal.]
11. Undo and remove the two bolts (arrows) securing the alternator. [Note: If the alternator is stuck in its bracket, screw in the bolts (arrows) again except for the last two turns.Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.]
12. Remove alternator by taking it upwards out of the vehicle.
13. Drive threaded sleeve (A) about 4 mm in direction of arrow out of alternator housing. [Note: Free off stiff sliding sleeves or bushes of the alternator mounting. Otherwise, the clamping force of the sliding bushes will be too low even though the specified torque is set.]
14. Secure wiring retainer (arrow) on back of alternator in 3 o'clock position.
15. Fit earth wire on batteryA.
16. Always start engine and check belt running after completing work.

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