3.0L TDI

Generator, Coolant Cooled

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Hose Clamps Up To 25 mm Diameter (3094)

• Workshop Crane Drip Tray (VAS 6208)

• Hose Clip Pliers (VAS 6362)

Removal

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

- Pull off engine cover upward - arrows -.






- Remove the air filter housing. Refer to => Engine Mechanical, Fuel Injection and Glow Plug 23 Description and Operation.

- Open screw-type clamps - 1 - and - 2 -.






• All hose connections for charge air system are secured by spring-type clamps, screw-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 of charge air pipe - arrow -.






- Open screw-type clamp - arrow -.

- Remove both connecting hoses from vehicle.






- Remove the connecting pipe - 1 - to the turbocharger.






- Unscrew the mounting bolt in the center of the right charge air pipe - arrow -.






- Open screw-type clamp - 1 - and remove mounting bolt - 2 -. Slide charge air pipe - 3 - toward rear in direction of bulkhead.






• The charge air pipe - 3 - can have various configurations, depending on the exhaust gas standard. The illustration is only an example.

- Remove the front charge air pipe. Refer to - 1 - => Engine Mechanical, Fuel Injection and Glow Plug 21 Removal and Installation.






- Mark running direction of ribbed belt.


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

- Remove noise insulation. Refer to => Body
Exterior 50 Description and Operation.

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






- Remove mounting bolt of idler pulley - arrow -.






- Clamp off coolant hoses using (3094).






• For reasons of space, hose clamp must be disassembled if necessary.

- Loosen the spring clamps - 1 - and push the coolant hoses from the connections.






- Remove generator screws - arrows -.






- Remove generator from bracket.

- Disconnect harness connector of DF-wire - arrow -.






- Remove protective cap - arrow -.






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






- Remove generator upward and out of vehicle.

Installation

Install in reverse order of removal. Note the following:


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

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






• Coolant hose from cylinder block leads into - IN - connection of generator. - OUT - connection is fastened to the coolant pipe.







• 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, power steering pump) are secured in place.

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

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