Removing and installing alternator, 1.2 l 55 kW TDI common rail engine — VW

🧭 Before you start

Disconnect the battery and remove the engine cover, poly V-belt, cold-side charge air pipe and fan cowling. Take off the holders, unplug the DF cable, remove the B+ lead and cable bracket, undo the mounting bolts and lift the alternator out upwards. On installation, drive the threaded sleeve out about 4 mm, tighten to the assembly overview torques, refit the belt correctly, reconnect the battery and check belt running.

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

Don't miss

• Mark the top and running direction of the poly V-belt before removing it.
• Drive threaded sleeve (A) about 4 mm out of the housing before fitting the alternator.
• Make sure all ancillaries are bolted up before the belt goes back on.
• Follow the battery disconnection and reconnection procedure for this car.
• Run the engine and watch the belt track on the pulleys.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Disconnect battery .
2. Remove engine cover Power unit10Removing and installing engine cover.
3. ⚠ 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.
4. Remove charge air pipe on »cold« side Power unit21Removing and installing charge air pipe on »cold« side.
5. Remove air duct cowling with radiator fan V7Power unit19Removing and installing air duct with radiator fan -V7-.

6. Remove holders (1) and (3).
7. Unlock and separate connector of DF cable (3).
8. Lever off deflector cap (2). Undo securing nuts (1) and remove B+ wire.
9. Undo securing nuts (4) and remove cable bracket from alternator.
10. Undo and remove securing bolts (arrows) of alternator.
11. Remove alternator by taking it upwards out of the 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 sleeve (A) about 4 mm in direction of arrow out of alternator housing.
13. Tighten threaded connections to specified torque given in assembly overview .
14. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Connecting battery .
15. Start engine and check belt running.

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