3.0L TDI

Generator, Air Cooled

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

Removal

• When installing, reinstall all cable ties that were loosened or cut during removal in the same locations.

- With ignition switched off, disconnect battery Ground (ND) wire. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.






- Carefully remove engine cover successively from the 4 locking bolts- arrows -.

- Remove ribbed belt. Refer to => Engine Mechanical,
Fuel Injection and Glow Plug 13 Removal and Installation.

- Remove screws and remove front - 1 - and rear - 2 - noise insulation.






- Detach wiring harnesses - 1 - and - 2 - from generator.






- Free up electrical wiring harness.

- Use a screwdriver to pry out protective cap - arrow -.






- Remove mounting bolt of idler pulley - arrow -.






- Remove the bolts - arrows - and remove generator.






• If alternator sticks in holder, install screw again down as far as the last 2 turns.

• Carefully strike on bolt heads using flat side of hammer - doing this loosens sleeves of generator mount.

Installation

Install in reverse order of removal, observing the following:

• Replace self-locking nuts.

- Slightly drive back sleeves for retaining bolts in order for easier installation of generator.


Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.

- Install ribbed belt. Refer to => Engine Mechanical,
Fuel Injection and Glow Plug 13 Removal and Installation.

- Connect the battery.

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

- Tighten the threaded connections to the specification given in the assembly overview.