Removing and installing air-cooled alternator, 6-cyl. 3.0 l TDI engine — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

• Renewed: self-locking nut

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• If alternator is stuck on its bracket, unscrew bolts to 2 turns.Carefully hit bolt heads with flat side of hammer to release bushes of alternator mounting.

📋 Procedure

1. With ignition switched off, disconnect earth wire from battery .
2. Carefully pull engine cover panel successively from the 4 retaining pins (arrows).
3. Remove poly V-belt Engine13Dismantling and assembling engine; Removing and installing poly V-belt.
4. Remove right charge air pipe Power unit21Assembly overview - parts of right charge air coolling.
5. Drain off coolant Power unit19Draining and filling coolant.

6. Remove coolant hose to thermostat Power unit19Schematic diagram for coolant hoses.
7. Unscrew securing bolts and remove noise insulation at front (1) and rear (2).
8. Remove electric wiring (1) and (2) from alternator.
9. Expose electric wiring harness.
10. Lever off protective cap (arrow) using a screwdriver.
11. Remove securing bolt of idler roller (arrow).
12. Unscrew bolts (arrows) and remove alternator. [Note: If alternator is stuck on its bracket, unscrew bolts to 2 turns.Carefully hit bolt heads with flat side of hammer to release bushes of alternator mounting.] [Note: Renew self-locking nut.]
13. To facilitate positioning of alternator, knock back slightly bushes for securing bolts.
14. ⚠ Tight bushes of alternator mounting must be loosened; otherwise clamping force of bush is too low despite right torque. — Install poly V-belt Power unit13Dismantling and assembling engine; Removing and installing poly V-belt.
15. Connect battery.
16. Start engine and check belt is running correctly.
17. Tighten threaded connections to torques specified in assembly overview.

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