Generator, 2.0L FSI Turbo Engine

Generator, 2.0L FSI Turbo Engine

CAUTION!
When disconnecting and connecting the Battery (A), the procedure must be followed as described in the Repair information. Refer to --> [ Battery, Disconnecting and Connecting ] .

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Mandrel (T10060) or Locking Pin (T10060 A)

• Spring-type clip pliers (VAS 5024 A)

Removing

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

- Remove bolts - arrows -.





- Disconnect electrical connection - arrow -.





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





- Pull off 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 with connector couplings:





• Release connection by pulling locking clip - arrow -.

• Disconnect hose/pipe without tools.

- Disconnect connector coupling - arrow -.





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





- Remove bolts - arrows -.





- Remove hose from vehicle.

- Remove the connecting tube from the charge air cooler to the turbocharger.

CAUTION!
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.

- Slacken ribbed belt by pivoting tensioner with an SW 16 open end wrench in - direction of arrow - and secure tensioner using (T10060 A).





- Remove ribbed belt.

- Loosen bolts on coolant pipe - arrows -.





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

- Remove the generator mounting bolts - arrows -.





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





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





- Remove the wire retainer - arrow - from the generator.





- Remove the generator from the vehicle.

Installing

Install in reverse order of removal, noting the following:

CAUTION!
• 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 (generator, A/C compressor) are securely fastened.

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

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







- Install the wire retainer - arrow - securely on the rear side 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 with connector couplings:





• Connect hose/pipe without tools.

• Make sure retaining tabs lock securely - arrow -.

- Tighten all fasteners to specified values. Refer to --> [ Generator Tightening Specifications ] Generator Tightening Specifications.

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

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

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

- Turn off the engine.