Drive Belts, Mounts, Brackets and Accessories: Service and Repair

Accessory Assembly Bracket

Special tools, testers and auxiliary items required

• Locking Pin (T10060 A)

Removing

• All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.


Observe safety precautions when disconnecting the battery.

- Remove tool formed insert under luggage compartment floor covering.

- Remove cover - arrow - for battery compartment





- Remove formed insert from over the battery.

- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.





- Remove center noise insulation fasteners - 1 to 3 -.





- Remove right noise insulation fasteners - 1 to 3 -.





- Disconnect secondary air hose at position indicated by - arrow -.





- Free up air hose to Secondary Air Injection (AIR) pump.

- Remove top mounting bolts for fan shroud - top arrows -.





• Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

- Swing tensioning device in direction of - arrow - to relieve tension on the ribbed belt and then lock it in place using the (T10060 A).





- Remove ribbed belt.

- Free up coolant hose at bottom on fan shroud.





- Disconnect electrical connector - 3 - at secondary air injection (AIR) pump motor (V101) and free up electrical wiring.

- On vehicles with DSG transmission, remove coolant pipe bracket - 2 - to transmission oil cooler.

- Remove bolts - 1 -.

- Loosen bolt - 4 - and remove Secondary Air Injection (AIR) pump with bracket.

- Disconnect electrical harness connectors - 1 - for coolant fans at bottom on fan shroud.





- Remove mounting bolts for fan shroud at bottom - bottom arrows -.

- Pull out fan shroud downward with both fans.

- Disconnect electrical harness connector - 1 - for A/C clutch on A/C compressor and free up electrical wire.






The air conditioning refrigerant circuit must not be opened.

- Remove bolts - arrow - for A/C compressor.

- Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.

- Remove electrical wire - 1 - on generator.





- Separate the electrical connector - 2 -.

• Ignore - 3 -.

- Remove upper idler roller - 1 -.





- Remove mounting bolts - 2 - and - 3 - for generator.

• Generator can be removed from bracket only with the upper mounting bolt still installed.

- Remove generator from accessory assembly bracket.

- Remove generator downward and to the left.

- Disconnect electrical connector - 3 - at after-run coolant pump (V51) - 2 - and remove pump with coolant hoses - 1 - and - 4 - connected downward from rubber loops on bracket. Spray rubber loops with silicone-free lubricant, if necessary.





- Remove bolts - 1 to 5 - and remove accessory assembly bracket.





• Disregard - arrow -.

Installing

• Tightening specifications, refer to => [ Ribbed Belt Drive Component Overview ] Ribbed Belt Drive Component Overview

Installation is in reverse order of removal, note the following:

• Bolts - 1 - and - 2 - are fitting bolts.

- Next, hand tighten the bolts in sequence - 1 to 5 -.

- Then tighten bolts in sequence - 1 to 5 -.

- To make it easier to install the generator, drive the bushings for the retaining bolts back slightly.

- Install generator.

- Install A/C compressor.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.