2.0L

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Locking Pin (T10060 A)

Removing

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

- Disconnect connector coupling - arrow -.






- Loosen spring clamp - arrow -.






- Remove bolts - arrows -.






- Remove charge air hose from vehicle.

- Loosen the clamp - 1 - and pull the hose - 2 - off the EVAP canister.






• The bracket for the EVAP canister is shown removed in the following illustration. It is not necessary to remove the bracket in order to unlock the filter.

- Lift the tab - arrow - with a screwdriver and remove the EVAP canister - 1 - from the bracket - 2 -.






- Move the EVAP canister - 1 - to the side with the hose still connected.

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. The belt will fail if it installed opposite the running direction or if is installed incorrectly.

- Remove the ribbed belt.

- Remove both bolts - arrows - and move the coolant pipes and the hose - 1 - upward so that there is enough space to remove the generator.






• The coolant pipes and the hose can remain connected.

- Remove noise insulation.

- Remove A/C compressor bolts - arrows -.






- Disconnect the connector - 1 -.






- Remove third bolt - arrow - and remove A/C compressor from bracket.

• Hoses on A/C compressor can remain connected.






• Tie the A/C compressor to a suitable place under the vehicle with wire - 1 - until it is ready to be installed.

• Make sure that hoses - 2 - are not stretched or kinked.

- Remove both lower bolts - arrows - on the generator.






- Disconnect the connector - 2 -.






- Remove both upper bolts - arrows - on the generator.

- Turn the generator slightly to the left in order to be able to access the connections on the back of the generator.

- Disconnect the DF lead connector - 1 -.






- Pry off cap - 1 -.






- Remove the nut - 2 - and B+ wire - 1 - below from generator connector threads.






- Remove generator upward and out of vehicle.

Installing

Install in 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 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!

Observe notes for threaded connections of battery terminals in => Electrical Equipment.

- Tighten all threaded connections to the specification shown in => [ Generator Overview ] Generator Overview.

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

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

- Turn off the engine.