Alternator: Service and Repair

Generator, Removing And Installing

See Caution before beginning repairs on the electrical system.

- Note and if necessary, determine radio code for vehicles equipped with coded anti-theft radio/radio navigation system only foreign brands).
- Switch ignition off and disconnect battery Ground (GND) strap.

N0TE: Steps after reconnecting voltage supply.

Vehicles With 4-cylinder Engine

Special tools and equipment







- VAG 1306 drip tray for VAG 1202A







- VAG 1921 hose clip pliers

Removing

WARNING: Hot steam or hot coolant may escape when opening coolant reservoir, cover cap with rag and open carefully.

- 0pen cap of coolant expansion tank.
- Remove engine cover.







- For vehicles with auxiliary heater, remove bolts -arrows- for exhaust pipe of stationary heater/auxiliary heater on noise insulation.







- Remove bolts or quick release screws -1- and -2- and remove front noise insulation.
- Place VAG1306 Drip Tray beneath engine.







- Remove retaining clip -1- and remove Engine Coolant Temperature (ECT) Sensor -G2- item -2-
- Drain coolant only from radiator.







- Disconnect top coolant hose at coolant pipe -arrow-







- Unbolt Coolant FC (Fan Control) Control Module -arrow-, disengage control module and set it aside.







- Move ribbed belt tensioner in direction of arrow to release tension on ribbed belt.
- Remove ribbed belt from generator belt pulley.
- Release tensioner.







- Disconnect electrical harness connector -1-







- Remove upper and lower bolts -arrows-.
- Remove generator.
- Unscrew terminal D+.

Installing
Installation is reverse order of removal, paying attention to the following:







- Make sure the ribbed belt is seated and installed correctly.
- Fill up with coolant:
- Connect battery.
- Start engine and check running of belt.

Tightening torques

Component Nm
Generator to engine 23
Terminal 30/B+ to generator 16