2.0L TDI

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 => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

• Check the generator.

Removal

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

- Pull off engine cover upward - arrows -.






- Bring the lock carrier into the service position. Procedures


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!

- Remove the ribbed belt.

- Disconnect the connector - 1 -.






- Remove A/C compressor screws - arrows -.






• Hoses on A/C compressor can remain connected.

• Tie up the A/C compressor with wire until it is time to install it.

• Make sure the hoses are not pulled off or kinked.

- Disconnect the DF lead connector - 1 -.






- Pry off cap - 2 -.

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

- Remove nut - 3 - and remove wiring bracket - 2 - from generator.






- Remove both of the bolts - 1 - and the nut - 2 - for the fuel filter - 3 - and lay them aside. The fuel hoses can remain connected.






- Remove both generator mounting bolts - arrows -.






- Remove the generator upward and out of the vehicle.

Installation


• When installing an already used ribbed belt, note direction of travel marked when it was removed!

• Before installing the ribbed belt, make sure all components (generator, A/C compressor) are securely fastened.

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

Install in reverse order of removal, noting the following:

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






- Screw wire retainer - arrow - firmly to rear side of generator in 3 o'clock position.







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

- Tighten the threaded connections to the specification given in the assembly overview, refer to => [ Generator Overview ] Generator Overview.

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

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

- Turn off the engine.