Removing and installing air cooled alternator, 6-cyl. 3.2 l fuel injection engine — VW

🧭 Before you start

Fits: VW Touareg I (7L, 2002–2010)

📋 Procedure

1. ⚠ When batteries are disconnected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the battery isolator may be triggered and the electrical equipment of the vehicle may be damaged. — Disconnect battery .
2. Disconnect DF wire connector (1) and pull off protective cap (2).
3. Unscrew B+ (battery positive) wire (arrow) from alternator.
4. ⚠ Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! — Remove air guide over radiator.
5. Screw pressure bolt M8 x 50 (arrow) into threaded hole of tensioning roller until poly V-belt can be removed.

6. ⚠ The tensioning roller housing may be damaged.The housing may be damaged if the hexagon bolt is screwed too far into the tensioning roller housing.Screw bolt in only enough to allow poly V-belt to be removed. — Remove securing bolts for tensioning roller (arrows).
7. Remove poly V-belt together with tensioning roller.
8. Remove securing bolts M8 x 90 of alternator (arrows).
9. ⚠ When installing used poly V-belts observe the direction of rotation marked on removal!Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioner compressor, vane pump) are secure.When fitting belt, ensure that poly V-belt seats correctly in pulleys!Ensure that the M8x50 pressure bolt is removed from tensioning roller. — Drive threaded sleeve (A) about 4 mm in direction of arrow out of alternator housing.
10. Tighten threaded connections to torques specified in assembly overview .
11. ⚠ When batteries are reconnected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the battery isolator may be triggered and the electrical equipment of the vehicle may be damaged.Observe notes for battery terminal clamp bolt . — Reconnect battery .
12. Start engine and check belt is running correctly.

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