Removing and installing alternator, 2.0 l TDI engine with no 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 out oil dipstick.
3. Pull engine cover upwards (arrows A) and forwards (arrow B) off engine.
4. Remove securing bolt (1).
5. Pull off vacuum hoses (2) and remove vacuum reservoir (3).

6. Disconnect DF wire connector (1) and pull off protective cap (2).
7. Unscrew B+ (battery positive) wire (arrow) from alternator.
8. Pull fuel filter out of bracket and place to one side. When doing this, the fuel hoses can remain connected.
9. ⚠ 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.
10. Release tension on poly V-belt by swivelling tensioning element in direction of arrow using a 16 mm open-jaw spanner.
11. Lock tensioning element using locking pin T10060 A.
12. Remove poly V-belt.
13. Remove securing bolts of alternator (arrows).
14. Unbolt cable retainer from alternator (arrow).
15. Remove alternator.
16. Drive threaded sleeves (A) about 4 mm in direction of arrow out of alternator housing.
17. ⚠ 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 .
18. Start engine and check belt is running correctly.

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