Generator

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Mandrel (T10060 A)


Follow the procedure in the Repair Information when disconnecting and connecting the battery. Refer to => [ Disconnecting and Connecting Battery In Engine Compartment ] Disconnecting and Connecting Battery In Engine Compartment.

Removal

- Disconnect the battery. Refer to => [ Disconnecting and Connecting Battery In Engine Compartment ] Disconnecting and Connecting Battery In Engine Compartment.

- Remove screws - arrows -.






- Open the retaining clips - arrows - and pull the hose out of the air filter housing.

- Disconnect electrical connection - 3 -.






- Pull off engine cover upward - arrows -.







Before removing ribbed belt, mark the top side and direction of travel. When installing, pay attention to correct running direction and installation position. If the belt is installed in the opposite running direction or is positioned incorrectly, the belt will fail!

- Mark running direction of ribbed belt.

- Release tension on ribbed belt by swinging tensioner using a 16 mm open-end wrench in - direction of arrow -.






- Lock the tensioner with the (T10060 A).






- Remove ribbed belt.

- Loosen the coolant pipe connections- arrows -.






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

- Remove mounting bolts for generator - arrows - (23 Nm).






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






- Remove the B+ wire - arrow - (15 Nm) from generator.






- Remove the wire retainer - arrow - (3.2 Nm) from generator.






- Remove generator from vehicle.

Installation

Install in reverse order of removal, noting 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 drive accessories (generator, air conditioner compressor) are secured in place.

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

- Drive threaded sleeves - A - out of generator housing approximately 4 mm in - direction of arrow -.






- Tighten wire retainer - arrow - (3.2 Nm) to rear side of generator.






• Make sure wiring harness is routed without tension.

- Tighten all threaded connections to the specification. Refer to => [ Generator Tightening Specifications ] Specifications.


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

- Connect battery. Refer to => [ Disconnecting and Connecting Battery In Engine Compartment ] Disconnecting and Connecting Battery In Engine Compartment.

- Start the engine and verify that the belt is running properly.

- Turn off the engine.