Generator
Generator C
• The Generator (C) is also known as a compact generator.
CAUTION!
Disconnect the battery (A) before working on the electrical system. Refer to => [ Battery A, Disconnecting and Connecting ] Battery A, Disconnecting and Connecting.
Generator
• First determine if a coded anti-theft radio is installed. In this case obtain the anti-theft security code.
• After connecting the Battery (A), check any affected system or component (radio, clock, comfort system, power windows) according to the repair information and/or the Owner's Manual.
CAUTION!
Disconnect the Battery (A) before working on the electrical system. Refer to => [ Battery A, Disconnecting and Connecting ] Battery A, Disconnecting and Connecting.
CAUTION!
If the Generator (C) is being replaced on a vehicle built between 07.04.2005 and 07.13.2007, then an adapter cable must be installed to the instrument cluster. Refer to => [ Adapter Cable, Installing ] Instrument Cluster!
4-Cylinder Gasoline and Diesel Engines
Special tools, testers and auxiliary items required
• Torque Wrench (VAG 1331)
CAUTION!
If the Generator (C) is being replaced on a vehicle built between 07.04.2005 and 07.13.2007, then an adapter cable must be installed to the instrument cluster. Refer to => [ Adapter Cable, Installing ] Instrument Cluster!
Removing
- Remove the engine cover.
- Remove the air filter housing.
- Remove the ribbed belt tensioning damper.
• From MY 2000, Generators (C) with a new design and new terminal designations are being installed.
• The differences between the new Generator (C) and the previously installed Generator (C) are:
• revised Voltage Regulator (C1);
• oval, radially sealed connector socket for 2-pin connector housing in place of previous, angular 2-pin connection
• revised terminal designation on the connections; refer to the wiring diagram
- Remove the nut - 1 - (terminal 30/B+) and disconnect the connector - 2 -.
- Remove the screw - 3 - on the clamp.
- Remove the screws on the Generator (C).
- Remove the Generator (C) upward.
Installing
Install in reverse order of removal, observing the following:
- Tap the threaded bushing - B - for the screws on the Generator (C) back about 1 mm before installing.
- Position the Generator (C) carefully on the bracket.
Tightening specifications, refer to=> [ 4-Cylinder Diesel Engine with Power Steering Assembly Overview ] Description and Operation.
5-Cylinder 2.5L Fuel Injection Engine
Special tools, testers and auxiliary items required
• Torque Wrench (VAG 1331)
CAUTION!
If the Generator (C) is being replaced on a vehicle built between 07.04.2005 and 07.13.2007, then an adapter cable must be installed to the instrument cluster. Refer to => [ Adapter Cable, Installing ] Instrument Cluster!
Removing
- Remove the engine cover.
- Disconnect the Battery (A). Refer to => [ Battery A, Disconnecting and Connecting ] Battery A, Disconnecting and Connecting.
- Remove the noise insulation and the ribbed belt guard.
- Remove the front section.
- Move lock carrier into the service position. Radiator Support
- Remove the carrier plate for the headlamp. Refer to => [ Halogen Headlamp Carrier Plate, From 07.2005 ] Halogen Headlamp.
- Remove the ribbed belt for the A/C compressor.
- Remove the ribbed belt that drives the power steering pump, the Generator (C), the coolant pump and the A/C compressor.
- Remove the A/C compressor.
- Disconnect the connector - 1 - and remove the nut - 2 - on the B+ wire.
- Remove the nut - 1 - and remove the clip - 2 -.
- Remove the nut from - 1 - from the bracket for the pressure line.
- Remove the bolts - arrows - on the belt pulley.
- Remove the bolts - arrows - from the power steering pump.
• Protect the lock carrier with tape when installing the power steering pump.
- Remove the power steering pump with the wires still connected and tie it to the lock carrier with wire.
- Loosen the nuts - arrows - all the way to the end of the threaded pin but do not remove them.
• Now it is possible to move the reservoir and the dryer making it easier to remove the Generator (C).
- Remove the (T 10060A) from the tensioner.
- Remove the screws - arrows - from the Generator (C).
- Remove the Generator (C) downward.
Installing
Install in reverse order of removal, noting the following:
- Install the Locking Pin (T 10060A) back into the tensioner before mounting the ribbed belt.
- Drive threaded sleeves - A - out of generator housing approximately 4 mm in - direction of arrow -.
Tightening specifications: Generator (C), refer to => [ 5-Cylinder Fuel Injection Engine with Power Steering and A/C Compressor ] Description and Operation.
B+ Wire Mount on Generator
B+ wire mount on the Generator (C) on vehicles built from 05.1999
• The B+ wire threaded connection on the Generator ( C) is identified by B1+!
• If the B+ lead is not tightened with the specified torque, the following may occur:
• The Battery (A) will not be completely charge.
• The complete electrical/electronics systems may fail (disabled vehicle).
• Fire hazard due to arcing.
• Damage to electronic components and control modules caused by excessive voltage.
- Tighten the B+ wire nut - arrow - to 15 Nm.
Vehicles with A/C system
• Opening the refrigerant circuit may be performed only in workshops having trained personnel and all the necessary tools and equipment.
• To avoid damage to condenser and A/C refrigerant circuit, do not bend or kink pipes and hoses.
CAUTION!
Do not open A/C refrigerant circuit.
- Remove the bolts - A - on the A/C compressor.
- Remove the A/C compressor from the bracket with all wires still connected.
• The right auxiliary fan must be removed if the vehicle has increased cooling system. Protect the radiator from damage using a piece of cardboard.
• Protect the bumper using tape.
- Tie the A/C compressor to the body in such a way so that the refrigerant lines/hoses are not under tension.
