Generator (GEN) - 165kW (225 bhp), Removing and Installing

Generator (GEN) - 4-Cylinder 165kW (225 bhp) Engine, Removing And Installing

CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch off all electrical consumers.
- Switch ignition off and remove ignition key.
- Disconnect negative ( - ) battery terminal.
- When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified.

Special tools, testers and auxiliary items needed

- VAG 1331 Torque wrench (or equivalent 5 - 50 Nm )

- T10060 Mandrel

Removing
- Disconnect battery

- Release fasteners -arrows- and remove engine cover.

- Remove cover in front of intake manifold -arrows-.

- Release fasteners -arrows- and remove left lock carrier cover -1-.

- Release fasteners -arrows- and remove right lock carrier cover -1- and expansion tank cover -2-.

- Release hose clamps and fasteners -arrows- and remove air pipe.

- Release hose clamps and remove vacuum pipe -2- from intake manifold.

NOTE: Disregard coolant hose -1-.

- Where applicable, disconnect electrical connector -arrow-.

- Remove bolts -2- and -3-.
- Pull holder -4- off guide tube for dipstick.
- Disengage coolant hose -1- from holder.
- Set aside holder with hoses connected.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.

- Loosen ribbed belt by turning tensioner in direction of -arrow-.

- Block tensioner with T10060.
- Remove ribbed belt.

- Disconnect electrical connector -2-.
- Remove nut from generator terminal B+ and remove connector eyelet from terminal.
- Remove harness retainer at generator.

- Remove bolts -arrows-.
- Lift generator from bracket and up to left of engine compartment.

Installing
Install in reverse order of removal, noting the following:
- Press sleeves into generator mounting to aid in installation.

CAUTION:
- Before installing the ribbed belt, make sure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.
- When installing belt, ensure correct seating in the belt pulleys.

- Note running direction of ribbed belt as previously marked and route as illustrated.
- Reconnect battery.
- Perform work steps specified in table.
- Start engine and check belt running.

Tightening torques

Generator to bracket - bolt 23 Nm
Terminal B+ to generator - nut 16 Nm
Secondary air pipe bracket to manifold - bolt 10 Nm
Secondary air pipe to bracket - bolt 10 Nm