Removing and installing alternator C, 1.6 l, 77 kW diesel engine — VW

Removing and installing
alternator
C
, 1.6 l, 77 kW diesel engine
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Caution
When disconnecting or reconnecting the
battery
A
, adhere strictly to the procedure described in the workshop manual
Chapter
.
Removing
Disconnect
battery
A
Chapter
.
Remove engine cover
Rep. gr.
10
Engine cover ; Removing and installing engine cover
.
Move lock carrier to service position
General body repairs, exterior
Rep. gr.
50
Lock carrier; Moving to service position
.
Caution
Prior to removal, mark top side and direction of rotation of 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
Rep. gr.
13
Cylinder block on pulley side; Removing and installing poly V-belt
.
Remove noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Assembly overview - noise insulation
.
Remove air conditioner compressor
Heating, Air conditioning
Rep. gr.
87
Air conditioner compressor; Removing air conditioner compressor from and installing on bracket
.
The hoses of the air conditioner compressor can remain connected.
Suspend the air conditioner compressor
3
using a piece of wire
1
at a suitable position under the vehicle until it is ready to be reinstalled. Ensure that the hoses
2
are not stretched or kinked.
Unlock and separate connector (DF cable)
1
.
Lever off deflector cap
2
.
Undo nut
1
and detach the B+ wire under it from the connecting thread of the
alternator
C
.
Undo nut
3
are remove wire holder
2
from
alternator
C
.
Undo bolts
1
and nuts
2
of the fuel filter
3
and place fuel filter
3
to one side. The fuel hoses can then remain connected.
Undo bolts
arrows
holding
alternator
C
in place.
Remove
alternator
C
.
Installing
Install in the reverse order of removal. When doing this, note the following:
Caution
When fitting used poly V-belts observe the direction of rotation marked on removal!
Before installing poly V-belt, make sure that all ancillaries (
alternator
C
, air conditioner compressor, power assisted steering vane pump) are secured tightly.
When fitting poly V-belt, make sure it is properly seated on the pulleys.
Drive threaded sleeves
A
roughly 4 mm in direction of
arrow
out of
alternator
C
housing.
Secure wiring retainer
arrow
on back of
alternator
C
in 3 o'clock position.
Tighten threaded connections to specified torque
Chapter
.
Reconnect
battery
A
Chapter
.
Start engine and check belt running.
Stop engine.