Removing and installing alternator, 1.6 l, 66/77 kW TDI engine — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

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• When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Disconnect battery .
• When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Connecting battery .

📋 Procedure

1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Disconnect battery .
2. Pull off engine cover panel upwards (arrows).
3. ⚠ Before removing, mark the top side and direction of rotation of the poly V-belt. When installing, ensure correct fitting position and direction of rotation. If the belt is installed in the wrong position or against direction of rotation, the belt will be destroyed! — Remove poly V-belt Power unit13Dismantling and assembling engine.
4. Remove sound proofing General body repairs, exterior50 Noise insulation.
5. Remove cowling with radiator fans V7 and V177 Power unit19Engine cooling system.

6. Remove charge air pipe (return union) "“cold side”" complete with upper and lower connecting hoses.
7. To do this, open upper spring-type clip (1). Release connector (3) on charge air pipe and disconnect. Remove bolts (2) and (4).
8. Release connector (1) and disconnect.
9. Remove securing bolts (arrows) of air conditioner compressor. [Note: The hoses of the air conditioner compressor can remain connected.Suspend the air conditioner compressor using a piece of wire at a suitable position until it is ready to be reinstalled.Ensure that the hoses are not stretched or kinked.]
10. Unscrew both securing bolts (1) and securing nut (2) of fuel filter (3) and place fuel filter to one side. The fuel hoses can then remain connected.
11. Unscrew upper securing bolt (2) of alternator.
12. Open lower spring-type clip (1).
13. Tilt alternator (3) forwards.
14. Unlock and separate connector of DF cable (3).
15. Lever off deflector cap (2).
16. Undo nut (1) and detach the B+ wire under it from the connecting thread of the alternator.
17. Undo securing nuts (4) and remove cable bracket from alternator.
18. Unscrew lower securing bolt (1) of alternator.
19. Remove alternator by taking it out of vehicle down to right. To do this, shift air conditioner compressor to left (as seen in direction of travel).
20. ⚠ When installing used poly V-belts observe the direction of rotation marked on removal!Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioning compressor) are secure.When fitting belt, ensure that poly V-belt seats correctly in pulleys! — Drive threaded sleeve (A) about 4 mm in direction of arrow out of alternator housing.
21. Secure wiring retainer (arrow) on back of alternator in 3 o'clock position.
22. Tighten threaded connections to specified torque given in assembly overview .
23. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Connecting battery .
24. Start engine and check belt running.
25. Stop engine.

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