Removing and installing alternator, 1.4 l 59 kW TDI engine with air conditioning system — VW

🧭 Before you start

Fits: VW Polo 9N (2001–2009)

• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: 16 mm ring spanner

📋 Procedure

1. Disconnect battery .
2. Pull the engine cover panel up first at the front (arrows) and then to the front.
3. Separate DF wire connector (1) and pull off protective cap (2).
4. Unscrew B+ wire (arrow) from alternator.
5. ⚠ Before removing, mark the top side and direction of rotation of the poly V-belt. When fitting, pay attention to correct direction and installation position. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! — Use a 16 mm ring spanner to swivel tensioning roller in (direction of arrow) until tensioning element can be locked with locking pin T10060A.

6. Remove poly V-belt.
7. Remove securing bolts (arrows) and remove tensioning roller.
8. Remove alternator securing bolts (arrows).
9. Remove wire holder (arrow) from back of alternator.
10. Remove alternator.
11. ⚠ When installing used poly V-belts observe the direction of rotation marked on removal!Before installing poly V-belt, make sure all assemblies (alternator, air conditioner compressor) are firmly in position.When fitting belt, ensure that poly V-belt seats correctly in pulleys! — Drive threaded sleeves (A) roughly 4 mm in direction of arrow out of alternator housing.
12. Secure wire holder (arrow) on back of alternator in 15 o'clock position.
13. Tighten all threaded connections to the specified torques .
14. Reconnect battery .
15. Start engine and check belt is running correctly.

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