Removing and installing alternator, 2.0 l TDI engine (4 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

Don't miss

• The fuel hoses remain connected.

📋 Procedure

1. Disconnect battery (see the separate procedure).
2. Pull engine cover panel upwards (arrows).
3. Pull off vacuum hoses (arrows).
4. Remove securing bolts (arrows).
5. Remove vacuum reservoir with bracket together.

6. Disconnect connector (1), pull off vacuum hose (2) and unclip line from retainer (3).
7. Unclip valve (4) and move aside.
8. Unscrew securing bolts (arrows) and remove bracket from intake manifold.
9. Disconnect DF wire connector (1) and pull off protective cap (2).
10. Unscrew B+ (battery positive) wire (arrow) from alternator.
11. Remove fuel filter and place it aside 4-cyl. 2.0 l, 4 valve diesel engine 20. Parts of fuel system. [Note: The fuel hoses remain connected.]
12. ⚠ 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.
13. Release poly V-belt tension by levering back tensioning element in direction of arrow using a 16 mm open-jaw spanner
14. Lock tensioning element using locking pin T10060 A.
15. Remove poly V-belt.
16. Remove securing bolts of alternator (arrows).
17. Unscrew wiring retainer (arrow) from alternator.
18. Remove alternator.
19. ⚠ 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.
20. Tighten cable retainer (arrow) to rear of alternator in 9 o'clock position.
21. Tighten threaded connections to specified torques (value given in the factory table, not available here).
22. ⚠ Observe notes for battery terminal clamp bolt (see the separate procedure). — Reconnect battery (see the separate procedure).
23. Start engine and check belt is running correctly.
24. Switch off engine.

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