Vehicles with TDI engine
Remove fuel filter and set aside 8 (do not disconnect hoses).
Vehicles with TDI engine and 1.2l, 1.4l, 1.8l TSI engines
Remove soundproofing. Remove the radiator fan along with the frame. Remove A/C compressor (do not open the refrigerant circuit) and fasten to the side so that the supply hoses are not overtightened. 1.8l TSI engine: Loosen hose clamps -2-, remove screws -arrows- and detach air intake hose.
Note: Seal open pipes with clean plugs from the plug set, eg -VAS 6122-.
1.2l TSI engine: Remove idler pulley, 1.4l TSI engine: Remove idler pulley.
All vehicles
Remove the shielding cap from the B+ wire fastening nut -1- and unscrew the nut. Disconnect connector -2-. Loosen the fixing nut (3.2 Nm) wire holder -3- or, depending on the engine, release the wire and move the wire to one side.
Vehicles with a three-phase current generator fixed on the side of the bulkhead - unscrew the screws - see. arrows- (23 Nm).
Note: If the alternator is clamped in the bracket, the screws must be screwed back in and then loosened by two turns. Carefully tap the flat side of the hammer on the screw heads. This will loosen the alternator mounting bushings.
Vehicles with alternator mounted on the side - Remove screws -arrows- (23 Nm). Remove the three-phase alternator towards the bottom.
Installation
Installation in reverse order. Vehicles with a three-phase current generator fixed on the side of the bulkhead - to facilitate installation, move the threaded bushings -A- approx. by 3 mm - see. arrows-. Observe the tightening torque for the B+ wire. Observe the procedure for performing work when connecting the battery. After completing the work, be sure to start the engine and check the belt running.
Fastening the B+ wire on a three-phase alternator
Carefully! The threaded connection of the B+ wire on the alternator is marked B1+! If the 8+ wire is fastened with a non-specified tightening torque, the following danger arises. The battery is not charging well. General failure of vehicle electronics. Risk of fire due to sparks. Damage due to increased voltage on electronic components and control units. For fixing the wire B + - see. arrow - always use new self-locking nuts.
Tightening torque of the self-locking nut for fastening the wire 8+ - see. arrow - is 20 Nm.
Checking the carbon brushes of a three-phase alternator
- Length of new carbon brushes = 12 mm
- Limit wear = 5 mm
- Permissible difference between carbon brushes relative to each other = +1 mm