Removing and installing alternator, vehicles with 2.0 l TDI engine — VW

🧭 Before you start

Disconnect the battery and remove the belt tensioner, right wheel housing liner front section and radiator cowl. Drain the coolant, remove the radiator hose and auxiliary heater exhaust pipe, then secure the AC compressor to the lock carrier without stressing its lines. Remove bolts (1), pull the alternator from its bracket, disconnect connector, B+ and clamp, and take it out downwards to the right. Slide the bushes back, refit in reverse, refill coolant and check the belt running with the engine started.

Fits: platform code 138

Don't miss

• Tie the AC compressor to the lock carrier so the refrigerant lines are not under tension.
• If the alternator is stuck, refit bolts to the last 2 turns and tap the heads to free it.
• Sliding bushes must move freely before refit, or clamping force is too low at specified torque.
• Coolant is drained for this job; refill and bleed the system before returning the car.
• Always start the engine and watch the belt run after completing the work.

Written for this job from the workshop steps below · TorqFix editorial.

📋 Procedure

1. With ignition switched off, disconnect earth cable from batteryA.
2. Remove tensioner for poly V-belt 13Cylinder block (pulley end); Removing and installing tensioner for poly V-belt.
3. Remove front part of right wheel housing liner 66Wheel housing liner; Removing and installing front wheel housing liner.
4. Remove radiator cowl 19Radiator/radiator fan; Removing and installing radiator cowl.
5. Drain off coolant 19Cooling system/coolant; Draining and filling coolant.

6. Remove coolant hose from radiator 19Radiator/radiator fan; Assembly overview - radiator/radiator fan.
7. Remove auxiliary heater exhaust pipe 82Auxiliary heater; Removing and installing exhaust system.
8. ⚠ 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 from bracket Heating, air conditioning system87Air conditioner compressor; Removing air conditioner compressor from and installing on bracket.
9. Secure air conditioner compressor to lock carrier so that refrigerant lines are not under tension.
10. Remove bolts (1). [Note: If the alternatorC(2) is stuck in its bracket, screw in bolts (1) again except for the last 2 turns.Carefully hit bolt heads with flat side of hammer to release sliding bushes of alternator mounting.]
11. Remove alternatorC(2) from bracket with electrical wiring still connected.
12. Disconnect connector (3).
13. Pry off cap (4).
14. Unscrew nut and remove terminal 30/B+ (5).
15. Unscrew nut (6) and pull off clamp (7).
16. Remove alternatorC(2) downwards to the right.
17. To facilitate positioning of alternatorC, 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.]
18. Reconnect batteryA.
19. Always start engine and check belt running after completing work.

Other VW procedures

• Removing engine · 41 torque figures
• Removing and installing camshaft – VW Golf Cabriolet · 47 torque figures
• Adjusting valve timing – VW Passat B5 · 83 torque figures
• Removing and installing camshafts – VW Passat B6 · 39 torque figures
• Removing and installing coolant pump · 53 torque figures
• Checking automatic headlight range control, headlights with gas discharge bulbs, vehicles up to 04.2011
• Removing and installing switches in centre of dash panel on right, Multivan
• Removing and installing anti-theft and tilt system control unit, roof console for Multivan
• Removing and installing starter, 4-cylinder diesel engine with automatic gearbox
• Removing and installing brake pads, brake caliper FN 44