Removing and installing alternator, 2.0 l TDI common rail injection engine — VW

🧭 Before you start

Disconnect the battery, remove the engine cover, set the lock carrier to service position and remove the fan duct and poly V-belt. Unbolt and suspend the air conditioning compressor, disconnect the DF wire, B+ lead and wiring retainer, move the fuel filter aside and remove the two alternator bolts. Refit with the threaded sleeve driven out about 4 mm and the cable retainer at 3 o'clock, then run the engine to check the belt.

Fits: platform code 137

Don't miss

• Mark the belt's top side and running direction before removal.
• Hang the compressor on wire with hoses connected; do not stretch or kink them.
• Fuel filter hoses stay connected when the filter is moved aside.
• Drive threaded sleeve (A) out about 4 mm before installing the alternator.
• Tighten the cable retainer at the rear in the 3 o'clock position.

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

📋 Procedure

1. Disconnect battery .
2. Pull engine cover panel upwards (arrows).
3. Place lock carrier in service position General body repairs, exterior50Moving to service position.
4. Remove air duct and fan motor Power unit19Removing and installing air duct with radiator fan -V7- and right radiator fan -V35
5. ⚠ 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 Power unit13Dismantling and assembling engine.

6. Release and disconnect connector (1).
7. Remove securing bolts of air conditioner compressor (arrows). [Note: The hoses of the air conditioner compressor can remain connected.Until reinstallation, suspend air conditioner compressor at a suitable position using a piece of wire.When doing this, ensure that hoses are not stretched or kinked.]
8. Release and disconnect DF wire connector (1).
9. Lever off protective cap (2).
10. Remove securing nut (1) and remove the battery positive wire, located beneath, from the connector thread of the alternator.
11. Unscrew securing nut (3) and remove wiring retainer (2) from the alternator.
12. 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.
13. Remove both securing bolts of alternator (arrows).
14. Lift alternator out of vehicle.
15. ⚠ 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 conditioning compressor) are securely mounted.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.
16. Tighten cable retainer (arrow) to rear of alternator in 3 o'clock position.
17. Tighten threaded connections to torques specified in assembly overview .
18. Reconnect battery .
19. Start engine and check belt is running correctly.
20. Switch off engine.

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