Removing and installing alternator, 1.8 l 110 kW turbo engine — VW

🧭 Before you start

Disconnect the battery, remove the engine cover and charge air hose, and unplug the alternator wiring. Mark and remove the poly V-belt, then take off the tensioning element and the two alternator bolts. Pull the alternator forward, release the wire retainer at the back and lift it out. On refitting, drive the threaded sleeve out about 4 mm, fit the cable holder in the 4 o'clock position, tighten everything to specification, refit the belt in its marked direction and check it running.

Fits: VW Polo 9N (2001–2009)

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

Don't miss

• Mark the top side and running direction of the poly V-belt before removal.
• Lock the tensioning element with T10060 A before taking the belt off.
• Drive threaded sleeve (A) about 4 mm out of the alternator housing before installing.
• Keep the wire retainer outside the tensioning element, not between it and the compact bracket.
• Mount the cable holder at the 4 o'clock position on the back of the alternator.
• Start the engine and watch the belt run true in every pulley.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. Disconnect battery .
2. First pull the engine cover panel up at the front and then to the front (arrows) and remove it from the vehicle.
3. Loosen hose clip and spring-type hose clip (arrows), pull the charge air hose (1) from both supports and remove it from vehicle.
4. Unfasten spring-type clip (3) and remove hose (2).
5. Open wiring retainer (1), remove hose (2) and place to one side.

6. Separate DF wire connector (1) and pull off protective cap (3).
7. Remove securing nut (located under cap) and disconnect B+ cable (2) from alternator.
8. ⚠ 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! — Release tension on poly-V-belt by swivelling tensioning element (1) in (direction of arrow) using a 16 mm open-jaw spanner.
9. Lock tensioning element (1) using locking pin T10060 A.
10. Remove poly V-belt.
11. Remove locking pin T10060 A and loosen tensioning element.
12. Remove the three securing nuts (arrows) and remove tensioning element from vehicle.
13. Remove both securing bolts on alternator (arrows).
14. Pull the alternator, taking different cable lengths into account, to the front off compact bracket and push it slightly in direction of headlight in order to access rear of alternator.
15. Remove securing nut (2) and remove wire retainer (1) from connector thread.
16. Lift alternator out of vehicle.
17. ⚠ 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 sleeve (A) about 4 mm in direction of arrow out of alternator housing.
18. Tighten cable holder (arrow) to rear of alternator in 4 o'clock position.Tensioning leverVAS 3297 [Note: When assembling tensioning device ensure that the wire retainer (1) is assembled outside of the tensioning element and not between the tensioning element and the compact bracket!]
19. Tighten threaded connections to specified torques .
20. Reconnect battery .
21. Start engine and check belt is running correctly.

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