Volkswagen Golf Service & Repair Manual: Removing and installing alternator, vehicles with TDI 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.
Remove tensioner for poly V-belt → Rep. gr.13.

Vehicles with air conditioner

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 from bracket → Heating, air conditioning system; Rep. gr.87.
Secure air conditioner compressor to lock carrier so that refrigerant lines are not under tension.

Continued for all vehicles

Remove bolts -arrows-.

Note If alternator -C--1- is stuck in its bracket, screw bolts in 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--1- from bracket with electrical wiring still connected.
Disconnect electrical connector -5-.
Pry off cap -4-.
Unscrew nut and remove terminal 30/B+ -3-.
Unscrew nut -6- and pull off clamp -2-.
Remove alternator -C--1- 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.

Reconnect battery -A- → Chapter.
Always start engine and check belt running after completing work.

Removing and installing alternator, vehicles with TDI engine