Generator

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Locking Pin (T10060)

Removal

- Disconnect the battery. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.


When disconnecting and connecting the Battery, the procedure must be followed as described in the repair information. Refer to=> [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

- Remove the engine cover upward - arrows A - and then forward - arrow B -.






• All hose connections for charge air system are secured by spring-type clamps or by connector couplings. The following must be observed for connector couplings:






• Release the harness connector by pulling the locking clamp - arrow -.

• Disconnect the hose/pipe without tools.

- Separate the couplings - 1 -.






- Unclip the fuel hoses - 2 - and remove the charge air hose.

- Remove the vacuum hose - 1 -.






- Disconnect the connector - 2 -.

- Remove the screw - 3 -.

- Remove the bolt - arrow -.






- Remove the noise insulation.

- Remove the bolt - arrow - from the charge air pipe.






- Disconnect the coupling - arrow - from the charge air pipe.






- Remove the charge air pipe upward.

- Disconnect the connector from the DF lead - 1 - and remove the cap - 2 -.






- Disconnect the B+ wire - arrow - from the generator.






- Pull the fuel filter out of the retainers and move it to the side. Fuel hoses can remain connected during this.


Mark the top of the ribbed belt and the running direction before removing it. Make sure the belt is installed correctly and pay attention to the running direction. If the belt is installed opposite to the running direction or is positioned incorrectly, the belt will fail!

- Mark the direction of travel of the ribbed belt.

- Move the tensioner in - direction of arrow - using a open-end wrench to release the tension on the ribbed belt.






- Secure the tensioning element with (T10060).






- Remove ribbed belt.

- Remove the bolts - arrows - from the generator.






- Remove the wire holder - arrow - from the generator.






- Remove the generator.

Installation

Installation is performed in the reverse order of removal. Note the following:


• When installing an already used ribbed belt, note direction of travel marked when it was removed!

• Before installing the ribbed belt, make sure all the components (the generator and the A/C compressor) are securely fastened.

• When installing the ribbed belt, make sure it is properly seated in the belt pulley!

- Remove the threaded bushings - A - from the generator housing approximately 4 mm in - direction of arrow -.






- Attach the wire holder - arrow - on the back of the generator in the 9 o'clock position.






• All hose connections for charge air system are secured by spring-type clamps or by connector couplings. The following must be observed for connector couplings:






• Connect the hose/pipe without tools.

• Make sure the retaining tabs are locked in place - arrow -.

- Tighten the threaded connections to the tightening specifications. Refer to => [ Generator Overview ] Generator Overview.

- Connect the battery. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.


Observe notes for threaded connections of battery terminals. Refer to => [ Battery Post/Terminal ] Battery Post/Terminal.

- Start engine and check belt routing.

- Turn off the engine.