Generator

Generator

When disconnecting and connecting the battery, always perform the work procedure as described in the repair information => [ Battery, Disconnecting and Connecting ] Service and Repair.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

Removal

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

- Release the clamp - 1 - and remove the hose - 2 - from the activated charcoal filter.






• The bracket for the EVAP canister is shown removed in the following illustration. It is not necessary to remove the bracket in order to unlock the filter.

- Use a suitable screwdriver to slightly lift the retaining tab on the back of the bracket - arrow - and remove the EVAP canister - 1 - upward from the bracket - 2 -.






- Put aside the EVAP canister - 1 - with the hose connected.

- Remove the noise insulation.

Mark the top of the ribbed belt and the running direction before removal. 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 both lower mounting bolts - arrows - of the generator from below.






- Release and disconnect the harness connectors - 2 - and - 3 -.






- Unscrew both oil pressure switches - 1 - and - 4 -.






- Unscrew both upper mounting bolts - arrows - of the generator.

- Tilt the generator slightly to the left in order to be able to access the connections on the back of the generator.

- Release and disconnect the harness connector of the DF wire - 1 -.






- Pry off the protective cap - 1 -.






- Remove the mounting nut - 2 - and disconnect the B+ wire - 1 - underneath it from the generator connection threads.






- Remove both mounting bolts - arrows - and move the pipes and the hose - 1 - upward so that there is enough space to remove the generator.






• The pipes and the hose can remain connected.

- Remove the generator from the vehicle in an upward direction.

Installation

Install in reverse order of removal. Note the following:

• 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!

- Remove the threaded bushings - A - from the generator housing approximately 4 mm in - direction of arrow -.






- Screw the wiring bracket - arrow - firmly to rear side of the generator in the 9:00 position.






- Tighten the threaded connections to the required tightening specification. Refer to => [ Generator Overview ] Generator Overview.

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

- Start the engine and check the belt routing.