Generator

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Spring-type Clip Pliers (VAS 5024 A)

• Locking Pin (T10060)

Removal


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.

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

- Remove the bolts - arrows -.






- Release and disconnect the harness connector - arrow -.






- Loosen the spring clamps - arrow - using (VAS 5024 A).






- Remove the engine cover upward - arrows -.






• 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 coupling - arrow -.






- Loosen the spring clamp - arrow - using (VAS 5024 A).






- Remove the bolts - arrows -.






- Remove the hose from the vehicle.

- Remove the pipe that connects the charge air cooler to the turbocharger.


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.

- Release the tension on the ribbed belt by moving the tensioner in - direction of arrow - using a open-end wrench and then secure the tensioner with (T10060).






- Remove ribbed belt.

- Loosen the threaded connections on the coolant pipe - arrows -.






• The coolant pipe can remain installed. It must be loosened in order to remove the generator.

- Remove the bolts - arrows - from the generator.






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






- Disconnect the B+ wire - arrow - 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.