alternator，0124615031，022903028BX,070903024,0121715004，022903028B,070903024B,070903139B,0124615031，0124625018,0124625028,0121615013,070903024A,for Volkswagen

Installation Method for 12V 180A Components (Taking Volkswagen Car Battery/Alternator as Examples)

I. Installation of 12V 180A Battery (General Process for Volkswagen Models)

• Confirm battery specifications: The 12V 180A (Ah) battery must match the original factory requirements of the model (commonly used in large-displacement Volkswagen models such as Magotan, Tiguan, etc.), and check the positive and negative pole layout and fixed base dimensions.

• Tool preparation: 10-13mm socket wrench, torque wrench, insulating gloves, rag (for cleaning the battery compartment).

• Power-off operation: If the vehicle has an old battery, first remove the negative (-) terminal, then the positive (+) terminal to avoid short-circuiting the two poles with tools.

• Clean the battery compartment: Remove dust and corrosion (wipe with baking soda water and dry before installing the new battery), and check that the fixed bracket is free of deformation and rust.

• Place the battery: Put the 12V 180A battery into the base, ensuring the positive and negative poles correspond to the original vehicle wiring (most Volkswagen models have "positive on the left, negative on the right"; some imported models are opposite, so verification is required).

• Fix the battery: Secure with a pressure plate and bolts according to original factory torque standards (generally 8-10N·m) to avoid damaging the battery case due to over-tightening.

• Connect the wiring: First connect the positive (+) terminal, tighten the terminal nut (torque 5-7N·m), and put on the insulating protective cover; then connect the negative (-) terminal, ensuring no loose connections (looseness may cause sparking and unstable voltage).

• Reset components: Reinstall the battery compartment cover and heat insulation cotton (if any), and check that surrounding wiring is free of extrusion and interference.

• Power-on test: Turn on the ignition switch, check that there are no fault lights on the dashboard (clear with a diagnostic tool if any), and test that the headlights, starter motor, audio, and other equipment function normally.

• Battery voltage detection: The voltage at idle should be 13.8-14.2V (normal alternator charging), and the static voltage after shutdown should be ≥12.5V.

II. Installation of 12V 180A Alternator (Volkswagen Models)

• Match the model: Confirm the alternator is compatible with the vehicle model (e.g., Volkswagen EA888 engine), and check the plug type (Bosch/Valeo type) and pulley specifications.

• Power off: Disconnect the negative battery terminal, and remove the engine decorative cover and air filter assembly (if needed).

• Remove the old alternator: Loosen the alternator fixing bolts and adjustment arm bolts, remove the drive belt; unplug the alternator plug (voltage regulator plug), and disconnect the positive terminal nut.

• Install the new alternator: Position the 12V 180A alternator, align with the fixing bolt holes, and pre-tighten the fixing bolts (do not fully tighten).

• Install the drive belt: Hang the belt according to the original factory belt routing diagram, adjust the alternator position to tension the belt (tension standard: press the middle section of the belt, deflection is about 10-15mm), then tighten the fixing bolts (torque 25-30N·m) and adjustment arm bolts (torque 20-25N·m).

• Connect the wiring: Plug in the voltage regulator plug, tighten the positive terminal nut (torque 8-10N·m), and wrap with insulating tape (if there is exposure).

• Reset components: Reinstall the air filter and engine decorative cover, and reconnect the negative battery terminal.

• Start the engine: Check that the alternator runs without abnormal noise at idle, and measure the battery voltage with a multimeter (13.8-14.2V indicates normal charging).

• Load test: Turn on high-power equipment such as headlights, air conditioning, and heating; the voltage should remain ≥13.5V without significant fluctuations.

III. General Precautions

• Strictly prohibit reversing the positive and negative poles (this will burn the vehicle's electronic control unit); apply anti-rust grease to the terminals (to extend service life).

• The 180A large battery weighs about 30kg; avoid collision during installation to prevent electrolyte leakage (for lead-acid batteries).

• Ensure moderate belt tension: Over-tightening may damage the bearings, while under-tightening causes slipping and insufficient power generation.

• Ensure the plug is fully connected to avoid loose connections that trigger the charging fault light.

• The 12V 180A components must match the vehicle's power load (e.g., models with start-stop systems or high-power audio); do not upgrade arbitrarily (this may exceed the carrying capacity of the original vehicle wiring).

General Precautions for Installation of 12V 180A Components (Battery/Alternator)

I. Precautions for Battery Installation

• Confirm that the dimensions (length × width × height) and terminal type (positive terminal/negative terminal) of the 12V 180A battery fully match the vehicle’s battery compartment to avoid unstable fixation or extrusion of surrounding wiring due to mismatched dimensions.

• Verify that the battery’s Cold Cranking Amperage (CCA) meets the model requirements (CCA of Volkswagen large-displacement/start-stop models is usually ≥800A). The 180Ah battery must match the corresponding power to prevent weak starting caused by insufficient power supply.

• Wear insulating gloves throughout the installation process. Do not touch both the positive and negative poles of the battery with metal tools at the same time (to prevent short-circuit sparking). Open flames and high-temperature sources are strictly prohibited near the battery (to avoid hydrogen explosion risks).

• Removal sequence of old battery: First remove the negative (-) terminal → then the positive (+) terminal; Installation sequence of new battery: First connect the positive (+) terminal → then the negative (-) terminal. Reversing the connection will burn out electronic control components such as the ECU and fuses.

• The terminals must be clean and free of oxidation (can be polished with sandpaper). Apply anti-rust conductive paste after connection to prevent poor contact caused by corrosion.

• Fix the battery with original factory pressure plates and bolts, and strictly control the torque at 8-10N·m. Over-tightening may crack the battery case, while under-tightening will cause the battery to shake during driving, damaging the terminals and wiring.

• Reinstall the battery heat shield (if available) to avoid the battery being baked by the engine’s high temperature and shortening its service life; the battery cover must be fastened to prevent electrolyte leakage from corroding the vehicle body.

• Let the battery stand for 5 minutes after installation before powering on to avoid instantaneous high-current impact on the battery; detect the idle voltage after starting the vehicle (13.8-14.2V indicates normal alternator charging).

• If the vehicle is equipped with an intelligent start-stop system, the battery must be matched with a diagnostic tool (input capacity and CCA value), otherwise the start-stop function will fail or the battery will be overcharged/discharged.

• References：

• I. Core Official Sources

• Volkswagen Original Factory Workshop Repair Manual

• Battery-related content: Refer to the chapter "Electrical System (Rep. gr.27) - Battery Removal and Installation" for Volkswagen models (e.g., Golf, Tiguan, etc.), which includes power-off sequence, fixing torque (8-10N·m), terminal connection specifications, and battery matching requirements for start-stop models (input capacity, CCA value). For example, the manual explicitly requires the installation of maintenance-free batteries that comply with TL82506 and VW75073 standards.

• Alternator-related content: Based on the chapter "Electrical System - Alternator Removal and Installation", it covers belt tension standards (deflection of 10-15mm when pressing the middle section), fixing bolt torque (25-30N·m), B+ terminal torque (8-10N·m), plug connection specifications, etc. Some models (e.g., EA888 engine series) also specify requirements for special tools (e.g., V.A.G 1331 torque wrench).

• Volkswagen Original Factory Technical Specifications and Standards

• Battery specification matching standards: Such as Volkswagen’s requirements for CCA value (≥800A) and capacity of batteries for large-displacement/start-stop models, as well as specifications for the layout of battery positive and negative poles.

• Wiring safety specifications: It explicitly prohibits disconnecting the battery wiring while the engine is running to avoid high-voltage breakdown of electronic control components, which is a general safety guideline for the maintenance of Volkswagen’s electrical systems.

• II. Industry General and Supplementary Sources

• General Operating Specifications of the Automotive Maintenance Industry

• The sequence of "connecting positive first then negative" for battery installation and "removing negative first then positive" for battery removal is a general safety operation specification in the automotive maintenance field to prevent short circuits and protect components such as the ECU, and is widely applied in the maintenance of various models.

• Requirements such as terminal cleaning, application of anti-rust conductive paste, and prevention of battery shaking during fixation are derived from conventional protection standards for automotive electrical maintenance, which can effectively avoid problems such as poor contact and battery damage.

•