Removing and installing alternator, 2.5 l TDI engine without air conditioning system — VW

Removing and installing alternator, 2.5 l TDI engine without air conditioning system
Caution
Please note the following points during all assembly work, in particular in the engine compartment, due to the narrow installation conditions:
Route electrical wiring so that original wiring layout is restored.
Make sure there is adequate clearance from all moving or hot components.
Alternator on vehicles with Start/Stop system:
Until now the alternator and the voltage regulator were connected together via their own wires to the engine and onboard supply control unit. For vehicles with Start/Stop system, the information transmission occurs via a LIN data bus to the diagnostic interface for data bus. Via the CAN data bus, it supplies information to other control units such as the engine control unit.
Special tools and workshop equipment required
Torque wrench (5 - 50 Nm)
V.A.G 1331
Torque wrench (40 - 200 Nm)
V.A.G 1332
Caution
The alternator should not be separated from the alternator bracket.
Do not loosen bolt connection between alternator and bracket.
If repair is required, remove, install or replace alternator complete with bracket.
Removing:
Alternator is removed downwards.
Caution
To disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to
Chapter
.
Disconnect battery
Chapter
.
Remove noise insulation
Rep. gr.
50
.
Moving lock carrier to service position
Rep. gr.
50
.
Using a screwdriver, carefully lever out sealing cap
1
on vibration balancer
4
.
Remove securing bolt
2
.
Remove vibration balancer
4
from subframe
3
.
Unscrew upper securing bolt
1
on support mounting.
Unscrew lower securing bolts
arrows
and remove support mounting.
Unscrew lower securing bolts
2
of torque reaction support.
Detach hose from bracket on upper part of torque reaction support above
left arrow
.
Unscrew securing bolts
arrows
and remove torque reaction support.
Release and disconnect electrical connector of DF cable
1
and pull off protective cap
2
.
Unbolt battery positive cable
arrow
from alternator.
Mark direction of rotation of elastic drive coupling.
Caution
The alternator should not be separated from the alternator bracket.
Do not loosen bolt connection between alternator and bracket.
If repair is required, remove, install or replace alternator complete with bracket.
Unscrew securing bolts
arrows
of alternator bracket.
Pull alternator off alternator drive. Remove alternator and elastic drive coupling downwards.
Installing:
Installation is carried out in the reverse order. When installing observe the following:
Note
In the event of damage, the elastic drive coupling must be replaced along with the alternator drive pulley.
Bolts loosened during removal of torque reaction support and support bearing must always be renewed.
Tighten threaded connections to specified torques
Chapter
“
Assembly overview - alternator, 2.5 l TDI engine without air conditioning system
”
.
Check that dowel sleeves for centring of alternator bracket/cylinder block are present. Install if necessary.
Screw in and tighten securing bolts
arrows
of alternator bracket.
Screw in and tighten securing bolts
arrows
securing torque reaction support to cylinder block.
Fit support mounting and slightly tighten upper securing bolt
1
.
Screw in and tighten lower securing bolts
arrows
on support mounting.
Tighten upper securing bolt
1
on support mounting to final torque.
Screw in and tighten securing bolts
2
for torque reaction support.
Connecting battery
Chapter
.