Removing and installing alternator, 4.9 l TDI engine: VW Phaeton

🧭 Before you start

Fits: VW Phaeton (3D)

• Opens: coolant

Don't miss

• The coolant hoses may remain attached to the coolant pipes.
• There are a total of 3 bolts which have to be brought into the proper position for removal by rotating the alternator shaft.
• Make sure the fitted sleeves (arrows) are present and are firmly seated. If necessary, fix loose fitted sleeves with commercially available grease before installation.

📋 Procedure

1. ⚠ When batteries are disconnected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the ignitor capsule of the pyrotechnical battery isolator may be triggered and the electrical equipment of the vehicle may be damaged. — Disconnect battery .
2. Drain coolant 10-cyl. diesel engine19Removing and installing parts of cooling system; Draining and filling coolant.
3. Remove fuel filter module 10-cylinder diesel engine20Removing and installing parts of fuel supply system; Removing and installing fuel filter.
4. Remove fuel rail from 10-cylinder diesel engine20Removing and installing parts of fuel supply system; Removing and installing fuel filter.
5. Remove upper part of oil filter housing 10-cyl. diesel engine17Removing and installing parts of lubrication system.

6. Remove intake manifolds 10-cylinder diesel engine23Diesel direct injection system; Removing and installing intake manifold.
7. Remove securing bolt (1) and remove bracket (2) for coolant pipe from alternator.
8. Pull coolant pipes (3) out of alternator. [Note: The coolant hoses may remain attached to the coolant pipes.]
9. Disconnect DF wire connector (1) and pull off protective cap (2).
10. Unscrew B+ (battery positive) wire (arrow) from alternator.
11. Remove securing bolt (1) and remove bracket (2) for battery positive wire from alternator.
12. Remove securing bolts (arrows) for alternator.
13. Remove securing bolts (arrows) for coupling. [Note: There are a total of 3 bolts which have to be brought into the proper position for removal by rotating the alternator shaft.]
14. Lift out alternator with coupling.
15. Remove alternator. Torsional elastic coupling (1) remains on the drive gear in this case. [Note: Make sure the fitted sleeves (arrows) are present and are firmly seated. If necessary, fix loose fitted sleeves with commercially available grease before installation.]
16. Tighten threaded connections to torques specified in assembly overviews:
17. Fill with coolant 10-cyl. diesel engine19Removing and installing parts of cooling system; Draining and filling coolant.
18. ⚠ When batteries are connected, the procedure described in the workshop manual must be strictly followed . If the sequence is not maintained, the ignitor capsule of the pyrotechnical battery isolator may be triggered and the electrical equipment of the vehicle may be damaged.Observe notes for battery terminal clamp bolt . — Reconnect batteries .

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