Alternator: Service and Repair
Alternator, removing and installingRemoving
1. Unscrew the negative pole from the battery.
2. For vehicles with air conditioning: loosen, but do not remove, fastening screws and nuts on the compressor plate.
Loosen lock nut from clamping screw and undo clamping screw.
Remove V-belt.
3. Remove protective cap and loosen hexagon nut (24 mm), countering with hook wrench Part No.911 721 703 00 or 999 571 047 02.
Remove V-belt.
4. Loosen three fastening screws on the air guide and fillister-head screw of the wide clamp.
5. Pull cooling fan with alternator out to the rear, loosen fastening nuts (3 each) of air box and slide box forwards.
6. Undo electrical connections and remove the blower to the rear.
7. Remove alternator with fan from the blower housing.
8. Pull fan from the alternator, use puller VW202 if necessary.
Adjust both puller hooks accordingly.
Remove disk.
Installing
1. Place disk between fan and alternator. Shouldered side points to the front alternator - shaft bearing.
2. Fasten electrical connections B+, D and 61. Ensure that the cables are laid correctly. See figure above.
3. Insert blower housing in the fitting pin on the crank case.
4. Tighten wide clamp, at the same time pressing the housing to the stop (in the direction of travel).
5. Fasten pulley.
Tightening torque: 40 Nm.
6. Check V-belt tension and adjust.