Removing and installing alternator, 2.5 l 5-cyl.

TDI engine Page 1 of 5

Removing and installing alternator, 2.5 l 5-cyl. TDI engine

Caution
The bolted connections between alternator and alternator bracket must not be loosened. In case of
repair, alternator and alternator bracket must be removed and installed or renewed together.

Special tools and workshop equipment required

t Torque wrench -V.A.G 1331/-
t Torque wrench -V.A.G 1332/-
t Support bracket -10-222 A-
t Adapter -10-222 A/8-
t Hook -10-222 A/10-

Removing:

Caution

When batteries are disconnected, the procedure described in the workshop manual must be strictly
followed → Chapter. If the sequence is not maintained, the battery isolator may be triggered and

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Removing and installing alternator, 2.5 l 5-cyl. TDI engine Page 2 of 5

the electrical equipment of the vehicle may be damaged.

– Disconnect battery → Chapter.

Note
The hose connections of the charge air system are secured by way of spring-type clips or push-
t
on connectors. The following points must be observed for push-on connectors:

Release push-on connection by pulling

t securing ring -arrow-.

t Pull off hose/pipe without tools.

– Unclip engine cover upwards -arrows-.

– Remove intake manifold → 5-cylinder
diesel engine; Rep. gr.23.
– Drain coolant → 5-cylinder diesel
engine; Rep. gr.19.
– Remove bonnet → General body
repairs, exterior; Rep. gr.55.

– Disconnect DF wire connector -1- and

pull off protective cap -2-.

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Removing and installing alternator, 2.5 l 5-cyl. TDI engine Page 3 of 5

– Unscrew B+ (battery positive) wire -

arrow- from alternator.

Unscrew the banjo bolt -arrow- from

–
the vane pump → Running gear, axles,
steering; Rep. gr.48.
– Remove pressure hose from vane pump
and lay hose to side.
– Seal off pressure hose and connection
of vane pump.
– Remove upper coolant pipe → 5-
cylinder diesel engine; Rep. gr.19.
Assemble support bracket from the
– following components: support bracket
-10-222 A-, two adapters -10-222 A/8-
and two hooks -10-222 A/10-.

– Support engine as shown in following

figure.

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Removing and installing alternator, 2.5 l 5-cyl. TDI engine Page 4 of 5

Remove left (from driver perspective)

–
pendulum support → 5-cylinder diesel
engine; Rep. gr.10.

Caution
The bolted connections between
alternator and alternator bracket must
not be loosened. In case of repair,
alternator and alternator bracket must be
removed and installed or renewed
together.

– Remove securing bolts for alternator

bracket -arrows-.
– Lift out alternator with bracket and
torsional elastic coupling.

Note
Locating sleeves are inserted in both
upper securing holes of alternator
bracket.
Installing:
Installation is carried out in the reverse
order. When installing observe the
following:

Note
Locating sleeves are inserted in both
upper securing holes of alternator
bracket.
– Check torsional elastic coupling for
damage.

Caution
The bolted connections between
alternator and alternator bracket must
not be loosened. In case of repair,
alternator and alternator bracket must be
removed and installed or renewed
together.

Note
The hose connections of the charge air
system are secured by way of spring-
t type clips or push-on connectors. The
following points must be observed for
push-on connectors:

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Removing and installing alternator, 2.5 l 5-cyl. TDI engine Page 5 of 5

t Push on hose or pipe without tools.

Ensure that locking lugs are securely
t
engaged -arrow-
– Fill with coolant → 5-cylinder diesel
engine; Rep. gr.19.

Note
The seals of the pressure hose must be
t
renewed.
Hydraulic fluid drained off is not to be
t
re-used.
– Check hydraulic oil level → Booklet.
Bleed steering system and check for
– leaks → Running gear, axles,
steering; Rep. gr.48.
Tighten threaded connections to torques
–
specified in assembly overview
→ Chapter.

Caution
When batteries are reconnected, the
procedure described in the workshop
manual must be strictly followed
t → Chapter. If the sequence is not
maintained, the battery isolator may be
triggered and the electrical equipment
of the vehicle may be damaged.
Observe notes for battery terminal
t
clamp bolt → Chapter.
– Reconnect battery → Chapter.

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