Removing and installing alternator with voltage regulator CX1, 2.0 l TDI engine, 103/125 kW — VW

Removing and installing
alternator with voltage regulator
CX1
, 2.0 l TDI engine, 103/125 kW
Caution
When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed
Chapter
.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Locking pin
T10060 A
Removing:
Disconnect battery
Chapter
.
Pull engine cover panel off upwards
arrows
.
Move lock carrier to service position
General body repairs, exterior
Rep. gr.
50
Lock carrier; 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-belts
Rep. gr.
13
Cylinder block on pulley side; Removing and installing poly V-belts
.
Remove noise insulation
General body repairs, exterior
Rep. gr.
66
Noise insulation; Removing and installing noise insulation
.
Unscrew both securing bolts
1
and securing nut
2
and place fuel filter
3
to one side. The fuel hoses can then remain connected.
Unscrew upper securing bolt
2
of alternator.
Open lower spring-type clip
1
.
Tilt alternator
3
forwards.
Unlock and separate connector of DF cable
3
.
Lever off protective cap
2
.
Undo nut
1
and detach the B+ wire under it from the connecting thread of the alternator.
Undo securing nuts
4
and remove cable bracket from alternator.
Unscrew lower securing bolt
1
of alternator.
Remove alternator by taking it upwards out of the vehicle.
Installing:
Install in the reverse order of removal. When doing this, note the following:
Caution
When installing used poly V-belts observe the direction of rotation marked on removal!
Before installing poly V-belt, make sure that all ancillaries (alternator, air conditioner compressor) are firmly secured.
When fitting belt, ensure that poly V-belt seats correctly in pulleys!
Drive threaded sleeve
A
about 4 mm in direction of arrow out of alternator housing.
Secure wiring retainer
arrow
on back of alternator in 3 o'clock position.
Tighten threaded connections to specified torque given in assembly overview
Chapter
.
Caution
When batteries are disconnected and reconnected, the procedure described in the workshop manual must be strictly observed
Chapter
.
Connecting battery
Chapter
.
Start engine and check belt running.
Stop engine.