2.5L

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

Removing

Always follow the instructions in the Repair Information exactly when disconnecting and connecting the battery. Refer to => [ Battery, Disconnecting and Connecting ] Service and Repair.

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

- Remove fan shroud.

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. If the belt is installed in the opposite running direction or is positioned incorrectly, the belt will fail!

- Remove the ribbed belt for the generator.

- Remove the idler roller - 1 - for the generator.






- Disconnect the connector - 1 - from the A/C compressor.






- If equipped, remove the refrigerant line from the A/C compressor.

- Remove the A/C compressor bolts - arrows -.






• The hoses on the A/C compressor can remain connected.

• Tie the A/C compressor to a suitable place on the vehicle with wire until it is time to install it again. Make sure the hoses are not pulled off or kinked.

• Make sure the hoses are not pulled off or kinked.

- Release the connector (DF lead) - 1 - and remove the cap - 2 -.






- Disconnect the B+ wire - arrow - from the generator.






- Remove the wire holder - arrow - on the back of the generator.






- Remove the screws - arrows - from the generator.






- Remove the generator.

Installing

Installation is performed in the reverse order of removal. Note the following:

- Drive the threaded sleeves - A - out of the Generator housing approximately 2 mm in direction of arrow.






- Attach the wire holder - arrow - on the back of the generator in the 9 o'clock position.






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

- Install the idler roller and ribbed belt tensioning roller for the generator.

- Tighten the nuts for the refrigerant lines on the longitudinal member to 10 Nm.

• When installing an already used ribbed belt, note direction of travel marked when it was removed!

• Before installing the ribbed belt, make sure all components (generator, A/C compressor, vane pump) are securely fastened.

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

- Install the ribbed belt.

Observe the information regarding the threaded connection of the battery terminals. Refer to => [ Battery Post/Terminal ] Battery Post/Terminal

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

- Start the engine and make sure the belt is running correctly.