5.0L TDI

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

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

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

Removal


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

Before removing generator, perform the following work procedures:

- Drain the coolant. Refer to => Engine Mechanical,
Fuel Injection and Glow Plug 19 General Information.

- Remove the intake manifolds. Refer to => Engine
Mechanical, Fuel Injection and Glow Plug 23 Removal and Installation.

• 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.






Installation

Install in reverse order of removal. Note 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. Refer to=> [ Generator with Torsion Elastic Clutch Overview ] Generator with Torsion Elastic Clutch Overview or => [ Generator with Hard Rubber Disc Clutch Overview ] Generator with Hard Rubber Disc Clutch Overview.

- Fill the coolant. Refer to => Engine Mechanical,
Fuel Injection and Glow Plug 19 General Information.


• When connecting battery, always perform work procedure as described in => [ Connecting Sequence ] One-Battery Layout with Auxiliary Battery and 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. Refer to => [ Battery Post/Terminal ] Battery Post/Terminal.

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