3.2L, 3.6L

Generator, Coolant Cooled

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Hose Clamps Up To 40 mm Diameter (VAS 3093)

• Bolt M8 x 50 (commercially available - pressure bolt for ribbed belt tensioner)

Removal


When disconnecting battery, procedure must always be followed as described in the repair manual. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting. If the sequence is not followed, the pyrotechnic battery isolation system switch may trigger, which may damage electrical components in the vehicle.

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

- Remove protective cap - arrow - of B+ wire.






- Remove the B+ lead - 1 - and separate the DF lead connector - 2 -.






- Clamp off coolant hoses using (VAS 3093).






- Remove bolt - arrow -.






- Pull coolant pipes off generator.

• The coolant hoses may remain connected to the coolant pipes.


Mark the top of the ribbed belt and the running direction before removing it. When installing, pay attention to correct running direction and installation position. The belt will fail if it installed opposite the running direction or if is installed incorrectly.

- Install pressure bolt M8×50 - arrow - in tensioner threaded bore until ribbed belt can be removed.







Only screw the bolt in so far until the ribbed belt can be removed. Otherwise, tensioner housing can be damaged.

- Remove bolts for tensioner - arrows -.






- Remove the ribbed belt together with the tensioner.

- Remove generator mounting bolts M8 x 90 - arrows -.






- Remove generator from bracket.

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, power steering pump) are secured in place.

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

• Make sure that the pressure bolt M8 x 50 is removed from the tensioner.

Install in reverse order of removal. Note the following:

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

- Remove pressure bolt M80 x 50 from tensioner.

- Fill with coolant. Refer to => Engine Mechanical,
Fuel Injection and Ignition 19 General Information.


• When connecting the battery, always perform the work procedure as described in the repair manual. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting. If the sequence is not followed, the pyrotechnic battery isolation system switch may trigger, which may damage electrical components in the vehicle.

• Observe notes for threaded connections on battery poles. Refer to => [ Battery Post/Terminal ] Battery Post/Terminal.

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

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