Generator

Generator

• Only generators by Hitachi are delivered as replacement parts. The Delphi generator is no longer produced. Converting generator, Delphi to Hitachi --> [ Generator, Removing Delphi and Installing Hitachi ].

• On generators with hard rubber disc clutch, this should generally be replaced with torsion-elastic clutch --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview.

--> [ Generator with Hard Rubber Disc Clutch ]

--> [ Generator with Torsion Elastic Clutch ]

--> [ Generator ]

--> [ Generator, Removing Delphi and Installing Hitachi ]

--> [ Generator One-Way Clutch ]

Generator with Hard Rubber Disc Clutch

• Only generators by Hitachi are delivered as replacement parts. The Delphi generator is no longer produced. Converting generator, Delphi to Hitachi --> [ Generator, Removing Delphi and Installing Hitachi ].

• On generators with hard rubber disc clutch, this should generally be replaced with torsion-elastic clutch --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331/)

Removing

CAUTION!
When disconnecting battery, procedure must always be followed as described in the repair information --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

- Disconnect battery --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting.

Before removing generator, perform the following work procedures:

- Drain coolant.

- Remove fuel filter module.

- Remove upper section of oil filter housing.

- Remove intake manifolds.

- Remove the bolt - 1 - and remove the bracket - 2 - for the coolant lines from the generator.

- Remove coolant lines - 3 - from generator.

• The coolant hoses may remain connected to the coolant pipes.

- Separate the connector for the DF-lead - 1 - and remove the protective cap - 2 -.

- Remove the B+ lead - arrow - from the generator.

- Remove the bolt - 1 - and remove the bracket - 2 - for the B+ lead from the generator.

- Remove the mounting bolts - arrows - for the generator.

- Remove the bolts - arrows - for the clutch.

• There are a total of 3 bolts which, by turning the generator shaft, must be brought into the correct position to be removed.

- Lift out generator with clutch.

Installing

Install in reverse order of removal, noting the following:

- Convert generator to torsion-elastic clutch --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview.

• Check if alignment bushings are equipped and securely seated - arrows -. If alignment bushings are loose, coat them with commercially available grease before installing.

- Tighten the threaded connections to the tightening specifications in the assembly overview --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview or --> [ Generator with Hard Rubber Disc Clutch Assembly Overview ] Generator with Hard Rubber Disc Clutch Assembly Overview.

- Fill with coolant.

CAUTION!
• When connecting battery, always perform work procedure as described in repair information --> [ Battery, with Auxiliary Battery or Two-Battery Layout, Disconnecting and Connecting ] Battery, with Auxiliary Battery or Two-Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

• Observe notes for threaded connections of battery terminals --> [ Battery Post/Terminal ] Battery Post/Terminal.

- Reconnect battery --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting.

Generator with Torsion Elastic Clutch

• Only generators by Hitachi are delivered as replacement parts. The Delphi generator is no longer produced. Converting generator, Delphi to Hitachi --> [ Generator, Removing Delphi and Installing Hitachi ].

• On generators with hard rubber disc clutch, this should generally be replaced with torsion-elastic clutch --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331/)

Removing

CAUTION!
When disconnecting battery, procedure must always be followed as described in the repair information --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

- Disconnect battery --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting.

Before removing generator, perform the following work procedures:

- Drain coolant.

- Remove fuel filter module.

- Remove upper section of oil filter housing.

- Remove intake manifolds.

- Remove the bolt - 1 - and remove the bracket - 2 - for the coolant lines from the generator.

- Remove coolant lines - 3 - from generator.

• The coolant hoses may remain connected to the coolant pipes.

- Separate the connector for the DF-lead - 1 - and remove the protective cap - 2 -.

- Remove the B+ lead - arrow - from the generator.

- Remove the bolt - 1 - and remove the bracket - 2 - for the B+ lead from the generator.

- Remove the mounting bolts - arrows - for the generator.

- Remove the generator. When doing this, the torsion-elastic clutch - 1 - remains on the drive gear.

Installing

Install in reverse order of removal, noting the following:

• Check if alignment bushings are equipped and securely seated - arrows -. If alignment bushings are loose, coat them with commercially available grease before installing.

- Tighten the threaded connections to the tightening specifications in the assembly overview --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview or --> [ Generator with Hard Rubber Disc Clutch Assembly Overview ] Generator with Hard Rubber Disc Clutch Assembly Overview.

- Fill with coolant.

CAUTION!
• When connecting battery, always perform work procedure as described in repair information --> [ Battery, with Auxiliary Battery or Two-Battery Layout, Disconnecting and Connecting ] Battery, with Auxiliary Battery or Two-Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

• Observe notes for threaded connections of battery terminals --> [ Battery Post/Terminal ] Battery Post/Terminal.

- Reconnect battery --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting.

Generator

• Only generators by Hitachi are delivered as replacement parts. The Delphi generator is no longer produced. Converting generator, Delphi to Hitachi --> [ Generator, Removing Delphi and Installing Hitachi ].

• On generators with hard rubber disc clutch, this should generally be replaced with torsion-elastic clutch --> [ Generator with Torsion Elastic Clutch Assembly Overview ] Generator with Torsion Elastic Clutch Assembly Overview.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331/)

Removing

CAUTION!
When disconnecting battery, procedure must always be followed as described in the repair information --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

- Disconnect battery --> [ Battery, One-Battery Layout, Disconnecting and Connecting ] Battery, One-Battery Layout, Disconnecting and Connecting.

Before removing generator, perform the following work procedures:

- Drain coolant.

- Remove intake manifolds.

• To remove EGR valve, remove coolant pipe bolt - arrow -.

- Remove the bolt - 1 - and remove the bracket - 2 - for the coolant lines from the generator.

- Remove coolant lines - 3 - from generator.

• The coolant hoses may remain connected to the coolant pipes.

- Separate the connector for the DF-lead - 1 - and remove the protective cap - 2 -.

- Remove the B+ lead - arrow - from the generator.

- Remove the bolt - 1 - and remove the bracket - 2 - for the B+ lead from the generator.

- Remove the mounting bolts - arrows - for the generator.

- Remove the generator. When doing this, the torsion-elastic clutch - 1 - remains on the drive gear.

• Before order replacement parts required for repair.

1 Generator, Hitachi (07Z 903 021 E)
2 Coolant pipe/angled piece (07Z 121 132 H)
3 B+ wire (07Z 971 349 B)
4 Coolant pipe/T-piece (07Z 121 132 L)
- Remove generator --> [ Generator ] Generator.

- Replace coolant pipes.

- Replace B+ wire --> [ B+ Cable Mount to Generator ] Description and Operation.

- Install generator --> [ Generator ] Generator.

Generator One-Way Clutch

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1332/)

• Multi-point adapter (VAS 3400)

Removing

- Remove generator --> [ Generator with Torsion Elastic Clutch ] or --> [ Generator ].

- Tighten the generator in a vise at the attachment points.

Insert multi-point adapter (VAS 3400) - 1 - in generator freewheel pulley - 2 - using open end wrench 17 mm. Then, insert a multi-point socket insert M10 - 3 - into the generator shaft.

- Loosen the threaded connection by rotating clockwise, while counter holding with the box-end wrench.

- Hold free in place by hand and turn at generator drive shaft until the free can be removed.

Installing

Install in reverse order of removal, noting the following:

- First screw one-way clutch on generator driveshaft by hand until limit stop.

Torque wrench must be re-assembled for installing free as follows:

- Release the insert - 1 - and pull it from the handle - 2 -.

- Rotate the handle - 2 - of the torque wrench 180 degrees and re-insert the bit.

- Set the rotation direction of the torque wrench bit to "left."

- Counterhold multi-point adapter (VAS 3400) - 1 - using open end wrench 17 mm and tighten free by turning generator drive shaft toward left using torque wrench - 2 -. The tightening specification is 80 Nm.

- Tighten one-way clutch to generator shaft threaded connection to 80 Nm.