TorqFix

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

Removing and installing alternator, 1.6 l TDI engine, 66 kW and 77 kW on VW: 19 steps. What to remove, in what order, and what to check after.

Workshop procedure for VW — the exact step sequence and torque figures, straight from real workshop data.

19 steps

🧭 Before you start

Fits: platform code 521

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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 . — Reconnect battery .

📋 Procedure

  1. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Disconnect battery .
  2. Pull engine cover panel upwards (arrows).
  3. Place lock carrier in service position General body repairs, exterior50Moving to service position.
  4. ⚠ 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 Engine13Dismantling and assembling engine.
  5. Release and disconnect connector (1).
VW? Steps differ between engine variants — check this job against your exact car before you commit to it. Check my car — free →
  1. Remove 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 that the hoses (2) are not stretched or kinked when doing this.]
  2. Release and disconnect DF wire connector (1).
  3. Lever off protective cap (2).
  4. Remove securing nut (1) and remove the battery positive wire, located beneath, from the connector thread of the alternator.
  5. Unscrew securing nut (3) and remove wiring retainer (2) from the alternator.
  6. Unscrew both securing bolts (1) and securing nut (2) of fuel filter (3) and place filter to one side. The fuel hoses can then remain connected.
  7. Remove both securing bolts of alternator (arrows).
  8. Lift alternator out of vehicle.
  9. ⚠ 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 conditioner 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.
  10. Tighten cable retainer (arrow) to rear of alternator in 3 o'clock position.
  11. Tighten threaded connections to torques specified in assembly overview .
  12. ⚠ When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed . — Reconnect battery .
  13. Start engine and check belt is running correctly.
  14. Switch off engine.

Other VW procedures

Who makes these pages, and how

TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.

The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.

Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.

Seen a figure that does not match your manual? Write to us — we correct it and note when. support@torqfix.com

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Workshop data on this page last updated 20 Sep 2026.