Removing and installing alternator, 1.6 l 77 kW TDI common rail 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 .
• When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Connect battery .

📋 Procedure

1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Disconnect battery .
2. Remove engine cover Power unit10Removing and installing engine cover.
3. ⚠ 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.
4. Remove charge air pipe (1)Power unit21Parts of charge air cooling - Assembly overview.
5. Release and separate connector (1) on air conditioner compressor.

6. Unscrew securing bolts of air conditioner compressor (arrows). [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 until it is ready to be reinstalled.Ensure, when doing this, that the hoses (2) are not stretched or kinked.]
7. Unlock and separate connector of DF cable (1).
8. Lever off deflector cap (3).
9. Unscrew securing nut beneath and remove B+ wire.
10. Unscrew securing nut (2) and remove cable bracket from alternator.
11. Unscrew both securing bolts (arrows) of alternator.
12. Remove alternator downwards from vehicle.
13. ⚠ 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) about 4 mm in direction of arrow out of alternator housing.
14. Tighten threaded connections to prescribed torques .
15. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be adhered to . — Connect battery .
16. Start engine and check belt running.

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