TDI
Generator
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 ] Service and Repair.
- Carefully remove engine cover successively from the 4 locking bolts- arrows -.
- Remove both charge air pipe connecting hoses. This makes it easier to get to the generator.
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 is installed opposite the running direction or if is installed incorrectly.
- Remove the ribbed belt.
- Remove the noise insulation.
- Pry off the cap - arrow - with a screwdriver.
- Remove mounting bolt of idler pulley - arrow -.
- Remove the bolts - arrows - and the generator. Be careful of the connected wires.
• 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.
- Detach wiring harnesses - 1 - and - 2 - from generator.
- Free up the wiring harness and remove the generator from the vehicle.
Installation
Install in reverse order of removal, observing the following:
• Replace self-locking nuts.
Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.
- Move the bolt sleeves slightly to the rear to make it easier to install the generator.
- Install the ribbed belt.
- Connect battery. Refer to => [ Battery, Disconnecting and Connecting ] Service and Repair.
- Start the engine and verify that the belt is running properly.
- Tighten the threaded connections to the specification given in the overview. Refer to => [ Generator Overview ] Generator Overview.