Removing and installing alternator, 1.9 l TDI engine with DSG — VW

🧭 Before you start

Fits: VW Touran I (1T, 2003–2015)

• 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 plug-in 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 pull off charge air hose (2).
4. Pull securing clip (3) and take charge air hose out of vehicle.
5. Disconnect DF wire connector (1) and pull off protective cap (2).

6. Unscrew B+ (battery positive) wire (arrow) from alternator.
7. ⚠ 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.
8. Release tension on poly V-belt by swivelling tensioning element in direction of arrow using a 16 mm open-jaw spanner.
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. Drive threaded sleeves (A) about 4 mm in direction of arrow out of alternator housing.
15. Tighten cable retainer (arrow) to rear of alternator in 3 o'clock position. [Note: All hose connections of charge air system are secured with spring-type clips or plug-in 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. ⚠ 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, vane pump) are secure.When fitting belt, ensure that poly V-belt seats correctly in pulleys! — Tighten threaded connections to torques specified in assembly overview .
17. Start engine and check belt is running correctly.

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