Alternator Pulley / Clutch: Service and Repair

Ribbed belt (Generator) pulley, removing and installing





Remove and install Generator (GEN) V- belt pulley using special tool 3310.

Tightening torque: 65 -/+ 5 Nm (48 +/- 3 ft lb)

Note:

Special tool 3310 is included in VW Special Tool Package AT- 119 (USA) and AT 000 119 (Canada).

Generator ribbed belt pulley with freewheel clutch (4-cylinder TDI engine with Bosch generators only), removing and installing

Generator ribbed belt pulleys on 4-cylinder TID engines (with Bosch generators only) may be equipped with a freewheel clutch.


The freewheel clutch momentarily freewheels drive to the pulley/generator whenever the ribb belt whips or oscillates due to variable belt loac (for example, during A/C operation or when switching on high current electrical consumers etc.). The freewheel clutch ensures driving forc to the generator is applied in a clockwise rotati only.


Notes:

- Before proceeding with any generator/volta regulator checks on Bosch generators with freewheeling clutch, always check operatio~ clutch flrsL

- Torque wrench needed to install generator pulley with freewheel clutch must be capab applying torque in a counter-clockwise direction!



Removing





- Remove protective cap from pulley and inse multitooth adapter 3400 and insert 6 mm hex socket into end of generator shaft.

- Counter-hold adaptor 3400 with 17 mm wrench and turn hex socket clockwise to loosen/remove pulley assembly.



Installing

- Insert multitooth adapter 3400 in pulley.

- Screw pulley assembly by hand onto generator shaft until stop is reached (if necessary, counter hold generator shaft with 6 mm hex socket).

- Insert 6 mm hex socket into end of generator shaft.

- While counter holding adaptor 3400 with 17 wrench, turn hex socket attached to torque wrench counterclockwise, and torque to 80 (59 ft lb).

CAUTION! Due to the high load applied to the ribbed belt the freewheel clutch pulley assembly must be torqued as specified. If not torqued, the pulley assembly could malfunction and affect generator operation.

- Install protective cap onto pulley.



Retrofitting

Note: Pulley with free wheel clutch may only be retrol onto Bosch generators. Retrofit is not possible Valeo generators!

- Remove existing ribbed belt pulley.

- Follow installation instructions above.



Torque wrench modification





- Release socket drive -1- (in most cases a securing pin must be removed) and detach from grip -2-.

- Turn torque wrench grip -2-, 180 and reinsert socket drive.

- Set turn direction on socket drive to counter-clockwise.

- Set torque to 80 Nm (59 ft lb).

- Proceed with pulley installation.