Removing and Installing Alternator

1. Disconnect battery.
2. Remove V-belt(s).
3. Take off protective cap.
4. Undo hexagon head nut (24 mm A/F), using a multi-tooth wrench (included in car tool kit) to lock.
5. Press fan wheel off generator, using puller VW 202 if required.


Installing





1. Fit generator into cooling fan housing. Make sure the connections for terminal B+ and terminal D+ are positioned opposite the TDC line mark (located on the edge of the cooling fan housing).
2. Fit fan wheel for generator. Apply a thin coat of Loctite 270 to generator shaft cooling threads and tighten to:
14 ±1 Nm (10 ±0.73 ft lb).

3. Apply grease to rubber grommet of generator wiring harness to facilitate fitting of the air guide shroud. Push cutout of air guide shroud into rubber grommet and screw air guide shroud into place using 4 fastening nuts.
4. Reconnect ground cable Locate ground cable on studs provided on crankcase and tighten to
23 Nm (17 ft lb).

5. Place cooling fan housing onto locating pin on crank with crankcase case. Push cooling fan housing up to the stop (in direction of travel) and tighten retaining strap at the same time.

CAUTION: When the generator is fitted correctly, the wiring harness must exit from the air guide shroud towards the right (in direction of travel).