Removing and installing alternator or compact alternator — VW

First check whether a coded radio is fitted. If this is the case obtain the anti-theft coding.

Warning!
Before working on the electrical system disconnect the battery earth strap.
Note:

When the battery is reconnected, please remember to check and reactivate vehicle equipment (radio, clock, convenience electrics, electric windows etc.) in accordance with Workshop manual and/or Owners manual.

Remove ribbed belt (poly V-belt), for description of work see relevant belt description =>page
27-65
.
Models with an air conditioning system => page
27-53
.
Remove ribbed belt tensioning element.

Notes:

Compact alternators with revised shape and terminal identification have been introduced as of model year 2000.
External distinguishing features of the new compact alternator compared to the compact alternator used previously.

Revised voltage regulator.
Oval, radially sealed connector fittings for the 2-pin connector housing in place of the previously used square corned 2-pin connector.
Revised terminal identification on connections.

=> See current flow diagram also.

Unscrew wire -1- (terminal 30/B+) and pull connector -2- off.
Unscrew cable clip -3-.
Unscrew alternator and take out upwards.

Vehicles with an air conditioning system

Warning!
The air conditioning refrigerant circuit must not be opened.
Notes:

The refrigerant circuit must only be opened in workshops with trained personnel and the necessary range of tools and workshop equipment.
To prevent damage to the condenser as well as to the refrigerant lines/hoses, ensure that lines and hoses are not stretched, kinked or bent.

Remove bolts -A- for air conditioner compressor.
Pull air conditioner compressor out of bracket with lines/hoses still connected.

Note:

For models with supplementary cooling, the supplementary radiator fan on the right must be removed first and the radiator protected from damage with a piece of cardboard.

Secure air conditioner compressor to body, so that the refrigerant lines/hoses are not stressed.

Note:

Protect bumper with adhesive tape to prevent damage.

Torque settings for bolts/screws:

=> Heating, air conditioning; Repair group 87; Removing and installing air conditioner compressor bracket
Heating, air conditioning
Removing and installing air conditioner compressor bracket

Continuation for all models:

Installing compact alternator

Drive the threaded sleeve -B-, for the alternator securing bolts, back approx. 1mm before reinstalling.
Fit alternator carefully onto compact bracket and tighten securely.

Securing B+ wire to alternator, models ▸04.99

Securing B+ wire to alternator, models 05.99 ▸

Note:

The threaded connection for the B+ wire on the compact alternator is marked with B1+!

Notes:

If the B+ wire is not secured with the prescribed torque the following may occur:

Battery not charge fully.
Vehicle electrics/electronics fail completely (breakdown).
Danger of fires from sparks.
Damage to electronic components and control units due to excessive voltage.

The prescribed torque setting for the B+ wire securing nut -arrow- is 15 Nm.

Secure wire -1- (terminal 30/B+) and tighten to 15 Nm and then fit connector -2-.
Secure cable clip -3-.

The rest of the assembly is basically in reverse order to the dismantling sequence.