Removing and installing alternator, 1.9 l and 2.0 l TDI engine (2 valves per cylinder) — VW

🧭 Before you start

Fits: VW Passat B6 (3C, 2005–2010)

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

📋 Procedure

1. Disconnect battery .
2. Pull engine cover panel upwards (arrows). [Note: All hose connections of charge air system are secured with spring-type clips or push-on connectors. The following points must be observed for push-on connectors:Release push-on connection by pulling securing ring (arrow).Pull off hose/pipe without tools.]
3. Loosen spring-type clip (1) using spring-type clip pliersVAS 5024 A and separate connector (2).
4. Remove charge air hose from vehicle.
5. Disconnect DF wire connector (1) and pull off protective cap (2).

6. Unscrew B+ (battery positive) wire (arrow) from alternator.
7. Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected.
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! — Mark direction of rotation of poly V-belt.
9. Lock tensioning element using locking pin T10060 A.
10. Remove poly V-belt.
11. Remove securing bolts of alternator (arrows).
12. Unbolt cable retainer from alternator (arrow).
13. Remove alternator.
14. ⚠ 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.
15. Tighten cable retainer (arrow) to rear of alternator in 9 o'clock position. [Note: All hose connections of charge air system are secured with spring-type clips or push-on connectors. The following points must be observed for push-on connectors:Push on hose or pipe without tools.Ensure that locking lugs are securely engaged (arrow)]
16. Tighten threaded connections to specified torques .
17. ⚠ Observe notes for battery terminal clamp bolt . — Reconnect battery .
18. Start engine and check belt is running correctly.
19. Switch off engine.

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