Alternator: Service and Repair

Generator (GEN) - 4-cylinder 1.8L Turbo Engine, Removing And Installing

Special tools, testers and auxiliary items required







- Drip tray VAG 1306 or drip tray for workshop crane VAS 6208







- Hose clip pliers VAG 1921







- VAG 133-Torque wrench (or 5-50 Nm equivalent)

Removing
- Disconnect battery.

CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.

- Open filler cap for coolant expansion tank.
- Remove engine cover.
- Lift vehicle.







- Release fasteners - 1 - and - 2 - and remove front noise insulation.







- Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 below engine.
- Pull off retaining clip - 1 - and pull out Engine Coolant Temperature (ECT) Sensor (on Engine) G83 -2-.
- Drain coolant from radiator only.







- Disconnect top coolant hose from coolant pipe - arrow-.







- Remove radiator fan control module - arrow - and set aside.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.







- Relieve ribbed belt tension by turning tensioner in direction of - arrow-.
- Remove ribbed belt from generator pulley.
- Release pressure from the tensioner.







- Disconnect electrical connection -1-.

NOTE: Electrical connections - 2 - and -3- not applicable to US/CDN models.







- Remove top and bottom bolts - arrows - and swing generator forward.







- Disconnect electrical connection - 2 -.
- Remove D+ terminal -1-.
- Remove generator.

Installing
Install in reverse order of removal, noting the following:

CAUTION:
- Before installing the ribbed belt, ensure that all subassemblies (generator, ale compressor etc.) are securely mounted and turn freely.
- When installing belt, ensure correct seating in the belt pulleys.
- Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.







- Note running direction of ribbed belt as previously marked and route as illustrated.
- Top up coolant.
- Reconnect battery. Required steps.
- Start engine and check belt running.

Tightening torques

Component - fastener Nm
Generator (GEN) to engine - bolt 23
Terminal 30/B+ to generator - nut 16