Removing and installing alternator, 1.2 l injection engine with air conditioning system — VW

Removing and installing alternator, 1.2 l injection engine with air conditioning system
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Removing
Disconnect earth wire from
battery
A
Chapter
.
Remove poly V-belt
Power unit
Rep. gr.
13
Cylinder block, belt pulley end; Removing and installing poly V-belt
.
Caution
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.
Unscrew the two securing bolts of air conditioner compressor
arrows
.
Release and disconnect connector
1
.
Undo the third bolt
arrow
and remove air conditioner compressor from bracket.
Note
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 under the vehicle until it is ready to be reinstalled.
Ensure that the hoses
2
are not stretched or kinked.
Release and disconnect connector
1
.
Pull off protective cap
arrow
.
Unscrew securing nut behind it and remove battery positive cable from alternator.
Undo bolt securing the guide roller
arrow
and remove guide roller.
Undo bolts securing alternator
arrows
.
Note
If the
alternator
C
is stuck in its bracket, screw in bolts again except for the last 2 turns.
Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.
Remove alternator by taking it downwards out of the vehicle.
Installing
Installation is carried out in reverse order of removal. Observe the following when doing this:
Drive threaded sleeves
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.
Fit earth wire on
battery
A
Chapter
.
Always start engine and check belt running after completing work.
Specified torques
Chapter
“
Assembly overview - alternator, 1.2 l injection engine with air conditioning system
”