Alternator: Service and Repair

Generator (GEN) - 6-Cylinder 184kW (250 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 )

Removing
- Disconnect battery.







- Release fastener -1- and remove cover in direction of -arrow-.

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







- Thread M8 x 40 bolt -arrow- into tensioner enough to relieve ribbed belt tension.
- Remove ribbed belt.







- Remove upper bolt -2-.
- Lift vehicle.







- Remove screws -1-, -2- and -3-.
- Remove center noise insulation panel.







- Remove screws -arrows-.
- Remove right noise insulation.







- Remove screws -arrows-.
- Remove left noise insulation.







- Remove bolts -arrows-.
- Remove cross brace.







- Remove bolts -arrows-.
- Suspend power steering pump from lock carrier (leave hydraulic hoses -1- and -2- connected).







- Disconnect electrical connector -1-.
- Remove bolts -arrow-.

CAUTION:
- Do not remove refrigerant hoses from a/c compressor.
- Have helper carefully lever engine to left when removing bolts. Loosen or remove engine/transmission mountings if necessary.

- Suspend a/c compressor from long member (leave refrigerant hoses connected).







- Remove lower bolt -1-.
- Remove generator from bracket (leave wiring connected).







- Remove harness retainer -3- at generator.
- Remove nut -1- from generator terminal B+ and remove connector eyelet from terminal.
- Disconnect electrical connector -2-.
- Remove generator.

Installing
Install in reverse order of removal, noting the following:

CAUTION:
- Engine/transmission mountings that may have been loosened or removed must be adjusted.
- 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.







- Remove M8 x 40 bolt -arrow- from tensioner.
- 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
A/C compressor to bracket - bolt 45 Nm
Power steering pump to bracket - bolt 23 Nm