2.5L

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.

- Remove the noise insulation.


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.

- Release and disconnect connector - 1 - and remove air conditioning compressor bolt - 2 -.






- Remove the both bolts - arrow - and remove the A/C compressor from the accessories bracket.






• Make sure that both centering sleeves are not lost.

• Hoses on A/C compressor can remain connected.






• Tie A/C compressor - 2 - to a suitable place with wire - 1 - until it is ready to be installed again.

• Make sure that connected hoses are not pulled off or kinked.

- Remove the both bolts - arrows - and then remove the lower idler roller - 1 - from the auxiliary component bracket.






- Remove the 3 bolts - arrows - and then remove the upper idler roller - 1 - from the auxiliary component bracket.






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






- Remove the nuts and disconnect the B+ lead - arrow - from the generator.

- Remove the wire holder - 3 - from the generator.

- Remove the bolts - arrows - and then remove the tensioning rollers - 1 and 2 -.






- Remove upper generator bolt - arrow -.






- Remove the screw on the bottom of the generator - arrow - and remove the generator.






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 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!

Install in reverse order of removal, noting the following:

• Before assembling the air conditioning compressor, make sure both centering sleeves are inserted in the threaded holes in the auxiliary component bracket.

- 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 8 o'clock position.







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

- 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.