Get Starter, current supply, CCS -> 2 Alternator Guide for Volkswagen Amarok Truck First Generation (2010-2022)

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

2

Alternator

⇒ o2.1 verview - alternator”, page 16

⇒ a2.2 nd installing alternator”, page 17

⇒ a2.3 lternator”, page 26

⇒ a2.4 lternator”, page 27

⇒ p2.5 oly V-belt”, page 32

2.1

Assembly overview - alternator

⇒ o2.1.1 verview - alternator, diesel engines”, page 16

⇒ o2.1.2 verview - alternator, petrol engines”, page 16

2.1.1

Assembly overview - alternator, diesel engines

1 - Bolts

❑ Qty. 2

❑ 20 Nm

2 - Alternator -C-

❑ Removing and instal‐

ling ⇒ page 17

❑ Checking ⇒ page 26

❑ Removing and instal‐

ling poly V-belt pulley ⇒

page 30

❑ Repairing alternator -C-

⇒ page 27

3 - Threaded bushes

❑ Qty. 2

4 - Electrical connector

5 - Nut

❑ 20 Nm

6 - Cover

7 - Terminal 30/B+

2.1.2

Assembly overview - alternator, petrol engines

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Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

1 - Alternator -C-

❑ Removing and instal‐

ling ⇒ page 17

❑ Checking ⇒ page 26

❑ Removing and instal‐

ling poly V-belt pulley ⇒

page 30

❑ Repairing alternator -C-

⇒ page 27

2 - Electrical connector

3 - Terminal 30/B+

4 - Nut

❑ 15 Nm

5 - Cover

6 - Bolts

❑ Qty. 4

❑ 25 Nm

2.2

Removing and installing alternator

⇒ a2.2.1 nd installing alternatorC, 4-cylinder petrol engines”,

page 17

⇒ a2.2.2 nd installing alternatorC, 4-cylinder diesel engines”,

page 20

⇒ a2.2.3 nd installing alternatorC, 6-cylinder diesel engines”,

page 25

2.2.1

Removing and installing alternator -C-,

4-cylinder petrol engines

Special tools and workshop equipment required

2. Alternator

17

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

♦ Hose clamps, up to 25 mm -3094-

♦ Torque wrench -V.A.G 1331-

Removing

– Disconnect battery ⇒ page 11 .

Note

Do not remove the entire poly V-belt, just detach it from the

pulley of the alternator -C-.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder

block on pulley side; Removing and installing poly V-belt.

– Detach hose clip -2-, and pull off charge air hose.

– Unscrew bolt -1-, and lay charge air pipe to one side.

– Clamp off coolant hose on upper radiator connection using

hose clamps up to 25 mm -3094- and pull off.

– Unscrew bolts -arrows-, and place bracket with radiator hose

to one side.

18

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Disconnect electrical connector -1-.

– Unscrew bolts -arrows-.

– Swing alternator -C- to side.

– Unscrew nut -2-.

– Remove alternator -C- upwards.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

Installing

Install in the reverse order of removal, observing the following:

– Connect battery ⇒ page 11 .

– Start engine, and check belt running.

Specified torques

♦ ⇒ o2.1.2 verview - alternator, petrol engines”, page 16

2.2.2

Removing and installing alternator -C-,

4-cylinder diesel engines

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Removing

– Disconnect battery ⇒ page 11 .

Note

Do not remove the entire poly V-belt, just detach it from the

pulley of the alternator -C-.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder

block on pulley side; Removing and installing poly V-belt.

– Remove charge pressure pipes -1- in area of alternator.

– Unscrew bracket of coolant line from engine at top -arrow-.

20

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Push coolant line -1- to one side and secure to fuel line

using a cable tie -2-.

Vehicles with auxiliary heater

Note

To ensure there is sufficient room for removing the alternator

on vehicles equipped with an auxiliary heater, release the auxil‐

iary heater far enough to be able to lift it with lines connected

⇒ Heating, ventilation, air conditioning system; Rep. gr. 82; Aux‐

iliary heater; Auxiliary heater; Removing and installing auxiliary

heater.

WARNING

Risk of burns.

Parts of the exhaust system may be hot.

Before removing the exhaust system, let it cool down.

– Remove auxiliary heater silencer together with bracket

⇒ Heating, ventilation, air conditioning system; Rep. gr. 82;

Auxiliary heater; Auxiliary heater; Removing and installing

silencer with bracket.

– Remove front left headlight -MX1- ⇒ page 105 .

– Unscrew bolt -arrow- from bracket for coolant pipes -1-.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew nut -arrow- through opening in headlight, and re‐

move coolant line -1-.

Note

For reasons of clarity, the following illustration shows the auxili‐

ary heater bracket without the auxiliary heater.

22

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew bolts -1-.

– Unscrew bolt -2-.

– Raise bracket and auxiliary heater with lines connected until

there is sufficient clearance to be able to remove the alterna‐

tor -C-.

Continued for all vehicles

– Disconnect electrical connector -1-.

– Lever off deflector cap -2-.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew nut and B+ wire under it from connecting thread of

alternator -C-.

– Unscrew bolts -arrows-.

– Remove alternator -C- from bracket, and turn it so rear side

is facing upwards.

– Use a long screwdriver to release retaining clip -arrow- of

wiring connector from alternator -C-.

– Remove alternator -C- -1- by removing it upwards from en‐

gine compartment.

Installing

Install in the reverse order of removal, observing the following:

Note

To facilitate positioning of the alternator -C-, slide the bushes on

alternator -C- slightly towards the rear.

– Connect battery ⇒ page 11 .

24

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Start engine, and check belt running.

Specified torques

♦ Specified torques for auxiliary heater ⇒ Heating, ventilation,

air conditioning system; Rep. gr. 82; Auxiliary heater; Auxili‐

ary heater; Removing and installing auxiliary heater.

♦ ⇒ o2.1.1 verview - alternator, diesel engines”, page 16

2.2.3

Removing and installing alternator -C-,

6-cylinder diesel engines

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Removing

– Disconnect battery ⇒ page 11 .

Note

Do not remove the entire poly V-belt, just detach it from the

pulley of the alternator -C-.

– Relieve tension from poly V-belt ⇒ Rep. gr. 13; Cylinder

block on pulley side; Removing and installing poly V-belt.

– Lever off cover -1-.

– Unscrew bolt -2-.

– Remove idler roller.

– Unscrew bolt -2- for air pipe.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew bolts -arrows-.

– Remove alternator -C- -4- from bracket.

– Unscrew nut -1-.

– Remove B+ wire -3-.

– Disconnect electrical connector -2-.

Installing

Install in the reverse order of removal, observing the following:

Note

To facilitate positioning of the alternator -C-, slide the bushes on

alternator -C- slightly towards the rear.

– Connect battery ⇒ page 11 .

– Start engine, and check belt running.

Specified torques

♦ ⇒ o2.1.1 verview - alternator, diesel engines”, page 16

2.3

Checking alternator

Check the alternator -C- using the ⇒ Vehicle diagnostic tester.

26

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

2.4

Repairing alternator

⇒ a2.4.1 nd installing voltage regulatorC1, Bosch”, page 27

⇒ a2.4.2 nd installing voltage regulatorC1, Valeo”, page 28

⇒ a2.4.3 lternator carbon brushes”, page 30

⇒ a2.4.4 nd installing poly V-belt pulley on alternator”, page 30

2.4.1

Removing and installing voltage regu‐

lator -C1-, Bosch

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Torque screwdriver -VAS 6494-

Removing

– Remove alternator -C- ⇒ page 17 .

– Unscrew nuts -1-.

– Unscrew bolt -2-.

– Remove protective cap -3-.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew bolts -arrows-.

– Carefully remove voltage regulator -C1- from alternator.

Installing

Install in the reverse order of removal, observing the following:

Specified torques

Component

Specified torque

Nuts -1- of protective cap -3-

Bolts -arrows-

15 Nm

2 Nm

2.4.2

Removing and installing voltage regu‐

lator -C1-, Valeo

Special tools and workshop equipment required

♦ Torque screwdriver -VAS 6494-

Removing

– Remove alternator -C- ⇒ page 17 .

– Lever protective cap -1- off alternator -C-.

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Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Unscrew bolts -2-.

– Remove voltage regulator -C1- -3- from alternator -C-.

Installing

Install in the reverse order of removal, observing the following:

– Press protective cap for carbon brushes -A- in

-direction of arrow- until it is flush with voltage regulator

housing.

Specified torques

Component

Specified torque

4 Nm

Bolts -2- for voltage regulator -C1-

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

2.4.3

Checking alternator carbon brushes

Note

The carbon brushes are permanently fixed to the voltage regu‐

lator. If repairs are necessary, renew the voltage regulator.

Checking

– Removing voltage regulator -C1- ⇒ page 17 .

– Measure length of carbon brushes, dimension -a-.

Carbon brushes

New

Length -a-

12 mm

Wear limit

5 mm

Tolerances to one another

+ 1 mm

2.4.4

Removing and installing poly V-belt

pulley on alternator

Special tools and workshop equipment required

♦ Multipoint adapter -3400-

30

Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

♦ Torque wrench -V.A.G 1332-

Removing

– Remove alternator -C- ⇒ page 17 .

– Clamp alternator in a vice.

– Lever protective cap off poly V-belt pulley.

– Insert adapter -3400- -1- into poly V-belt pulley using 17 mm

ring spanner.

– Then insert multipoint bit -M10- -3- in alternator shaft.

– Counterhold alternator shaft whilst releasing poly V-belt pul‐

ley by turning it anti-clockwise with ring spanner.

– Counterhold poly V-belt pulley by hand.

– Turn alternator shaft until poly V-belt pulley can be removed.

Installing

Install in the reverse order of removal, observing the following:

– Screw poly V-belt pulley by hand as far as stop onto drive

shaft of alternator.

Convert torque wrench -V.A.G 1332- as follows for installing

poly V-belt pulley:

– Release socket drive -1- and pull off grip -2-.

2. Alternator

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

– Turn torque wrench grip -2- by 180°, and reinsert socket

drive -1-.

– Set turning direction of torque wrench -V.A.G 1332- to anti-

clockwise at socket drive.

– Insert multipoint bit -M10- -1- into alternator shaft.

– Counterhold multipoint adapter -3400- -1- using ring spanner

(AF 17 mm).

– Tighten poly V-belt pulley by turning alternator shaft anti-

clockwise using torque wrench -V.A.G 1332-.

Specified torques

Component

Specified torque

80 Nm

Poly V-belt pulley on alternator shaft

2.5

Checking poly V-belt

– Crank engine at vibration damper on pulley using a socket.

– Check poly V-belt for:

♦ Sub-surface cracks (cracks, core ruptures, cross sectional

breaks)

♦ Layer separation (top layer, cord strands)

♦ Eruptions on underbody

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Rep. gr.27 - Starter, current supply, CCS

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

♦ Fraying of carcass

♦ Flank wear (material wear, frayed flanks, flank brittleness

-glassy flanks-, surface cracks)

♦ Traces of oil and grease

Caution

In order to avoid failures and malfunctions, the poly V-belt

must be replaced if it is damaged.

2. Alternator

33

Starter, current supply, CCS -> 2 Alternator for Your Volkswagen Amarok Truck First Generation (2010-2022)

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