Removing and installing alternator, 1.6 l, 63 kW and 77 kW injection engine — VW

🧭 Before you start

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

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• When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Disconnect battery .
• To gain easier access to the lower securing bolt on the alternator, the securing bolt for the relay roller may be loosened and the relay roller pulled off slightly.

📋 Procedure

1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Disconnect battery .
2. Unlock and separate connector of DF cable (1).
3. Lever off deflector cap (2).
4. Unscrew securing nuts (arrow) and remove B+ wire.
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 top securing bolt (arrows) of alternator.
7. Remove bottom alternator securing bolt (arrow). [Note: To gain easier access to the lower securing bolt on the alternator, the securing bolt for the relay roller may be loosened and the relay roller pulled off slightly.]
8. Pull alternator out of its installation position whilst considering connected cable lengths.
9. Unscrew securing nuts (arrow) and remove cable retainer from alternator.
10. Remove alternator upwards out of vehicle.
11. ⚠ 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.
12. Secure cable retainer (arrow) on back of alternator in 3 o'clock position.
13. Tighten all threaded connections to specified torque .
14. Connect battery .
15. Start engine and check belt running.

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