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

🧭 Before you start

Fits: platform codes 6S1, 6S2

• Timing position: the crankshaft or camshaft is set and locked during this job

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• To gain easier access to the lower securing bolt on the starter, the securing bolt for the relay roller may be loosened and the relay roller pulled off slightly.

📋 Procedure

1. Disconnect battery .
2. Separate DF wire connector (1) and pull off protective cap (2).
3. Unscrew battery positive wire (arrow) from alternator.
4. Remove noise insulation General body repairs, exterior50 Noise insulation.
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! — Release poly V-belt tension by levering back tensioning element in direction of arrow using a 16 mm open-jaw spanner.

6. Lock tensioning element using locking pin T10060 A(1).
7. Remove poly V-belt.
8. Remove upper alternator securing bolt (arrow).
9. Remove lower alternator securing bolt (arrow). [Note: To gain easier access to the lower securing bolt on the starter, the securing bolt for the relay roller may be loosened and the relay roller pulled off slightly.]
10. Pull alternator out of its installation position, as far as the connected wiring allows, and unscrew wiring retainer (arrow) on back of alternator.
11. Lift alternator out of vehicle.
12. ⚠ 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.
13. Secure wire holder (arrow) on back of alternator in 15 o'clock position.
14. Tighten all threaded connections to the specified torques .
15. Reconnect battery .
16. Start engine and check belt is running correctly.

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