Removing and installing alternator, 1.2 l 55 kW injection engine — VW

🧭 Before you start

Fits: platform codes 601, 602, 612, 641, 642, 643, 604, 644, 614, 603

Don't miss

• Ensure that the spacer sleeve on the lower securing bolt is not lost when removing the alternator!

📋 Procedure

1. Disconnect battery .
2. Unfasten connector (1) and disconnect.
3. Pull off protective cap (arrow).
4. Unscrew securing nut behind that and remove battery positive cable from alternator.
5. ⚠ Before removing, mark top and direction of rotation of poly V-belt. If the poly V-belt is installed in the wrong position or against direction of rotation, the poly V-belt will be destroyed! — Remove poly V-belt Power unit13Dismantling and assembling engine; Removing and installing poly V-belt.

6. Unscrew securing bolts of air conditioner compressor (arrows). [Note: When removing air conditioner compressor, watch out for centring sleeves and spacer bushes.The hoses of the air conditioner compressor can remain connected.Suspend the air conditioner compressor (3) using a piece of wire (1) at a suitable position until it is ready to be reinstalled.Ensure that the hoses (2) are not stretched or kinked.]
7. Remove bolt (arrow).
8. Remove bolt (2) and detach idler roller (1).
9. Remove bolt (arrow) and detach tensioning element (1).
10. Remove both securing bolts (arrows) of alternator. [Note: Ensure that the spacer sleeve on the lower securing bolt is not lost when removing the alternator!]
11. Remove alternator from vehicle.
12. ⚠ When installing previously used poly V-belts, ensure correct direction of rotation and installation position.If the poly V-belt is installed in the wrong position or against direction of rotation, the poly V-belt will be destroyed!Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioner compressor) are secure.When fitting poly V-belt, make sure it is properly seated on the pulleys. — Drive threaded sleeves (A) roughly 4 mm in direction of (arrow) out of alternator housing.
13. Insert spacer bush of lower alternator securing bolt.
14. Tighten all threaded connections to specified torque .
15. Connect battery .
16. Start engine and check belt running.

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