Removing and installing alternator C, vehicles with diesel engine — VW

Removing and installing
alternator
C
, vehicles with diesel engine
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1783
Removing
With ignition switched off, disconnect earth cable from
battery
A
Chapter
.
Remove poly V-belt
Rep. gr.
13
Cylinder block on pulley side; Removing and installing poly V-belt
.
If the tensioning device covers the lower securing bolt for
alternator
C
, remove tensioning device for poly V-belt
Rep. gr.
13
Cylinder block, belt pulley end; Removing and installing tensioning device for poly V-belt
.
Remove radiator cowl
Rep. gr.
19
Radiator/radiator fan; Removing and installing radiator cowl with radiator fan
.
Caution
Risk of damage to air conditioner compressor, refrigerant lines and refrigerant hoses:
Make sure refrigerant lines and hoses are not excessively stretched, kinked or bent.
Remove air conditioner compressor
3
with refrigerant lines
2
connected from bracket
Heating, air conditioning
Rep. gr.
87
Air conditioner compressor; Removing and installing air conditioner compressor
.
Use a piece of wire
1
to suspend air conditioner compressor
3
at a suitable position under the vehicle.
Release and disconnect connector (DF wire)
1
on
alternator
C
.
Pry off cap
2
.
Unscrew nut
1
and remove terminal 30/B+.
Unscrew nut
3
and pull off clamp
2
.
Remove bolts
arrows
.
Note
If the
alternator
C
is stuck in its bracket, screw in bolts
arrows
again except for the last 2 turns.
Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.
Remove
alternator
C
2
downwards to the right.
Installing
Install in the reverse order of removal, observing the following:
To facilitate positioning of
alternator
C
, slide bushes of alternator mounting slightly towards back.
Note
Ensure that bushes of alternator mounting slide freely and are not to tight (loosen, if necessary); otherwise clamping force of sliding bushes is too low even if specified torque is applied.
Secure wiring retainer
arrow
on back of
alternator
C
in 3 o'clock position.
Reconnect
battery
A
Chapter
.
Always start engine and check belt running after completing work.
Specified torques
Chapter
“
Exploded view - alternator with sliding bushes
”