Generator, 3.0L TDI Without Auxiliary Heater
Generator, 3.0L TDI without Auxiliary Heater
Special tools, testers and auxiliary items required
• Torx T60 Socket (T40087)
Removing
- Switch the ignition off.
- Disconnect the battery ground (GND) cable from the battery. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.
- Remove the engine cover in the direction of the - arrows -.
- Remove the air duct - arrow -.
- Disconnect the mass airflow sensor (G70) connector - 1 -.
- Remove the bolt - 3 - and free up the exhaust pressure sensor 1 (G450) - 4 - on the air guide pipe.
- Free up the exhaust gas temperature sensor 4 (G648) - 2 - connector on the air pipe.
- Remove the air guide hose with the mass airflow sensor (G70) by releasing the hose clamp - 5 - and opening the clips - arrows -.
- Disconnect the vacuum line - 1 -.
- Remove the air filter housing and on the rear side, disconnect the electrical connector - 2 - on the air filter bypass door valve (N275).
- Remove the screws - 2 - and - 3 -.
- Remove the air guide pipe from the air guide hose by loosening the hose clamp - 1 -.
- Remove the right front wheel.
- Loosen the front section of the right front wheel housing liner and press it back..
- Remove the front noise insulation - 1 -.
- Remove the bolt - 1 - and nut - 3 -.
- Remove the right lock carrier brace - 2 -.
Vehicles with DSG Transmission:
• Note the rules for cleanliness when working on the DSG transmission.
- Remove the bolt - arrow - for the automatic transmission fluid (ATF) lines.
All Vehicles:
- Disconnect the - 4 - right electrohydraulic engine mount solenoid valve (N145) connector.
- Remove the mount - 5 - for the connector on the bracket - 3 -.
- Remove the nut - 1 - and remove the bracket and wiring harness from the subframe.
- Cut the cable tie - 6 - and move the bracket and heat shield to the side.
- Remove the nut - 2 - and disconnect the ground wire on the longitudinal member.
- Remove the air guide hose from the right air guide pipe and lay it aside by loosening the hose clamp - arrow -.
Risk of destroying if the running direction of a used ribbed belt is reversed.
• Before removing ribbed belt, marking running direction with chalk or a felt-tip pen for reinstallation.
- Using a torx T60 socket (T40087) , move the tensioning element clockwise - arrow - to release the tension on the ribbed belt.
- Remove the ribbed belt from the generator ribbed belt pulley.
- Loosen the generator bolts - arrows - approximately 6 turns.
- Using a hammer, carefully hit bolt heads to loosen generator mount bushings.
- Remove the bolts completely.
- Remove generator from bracket.
- Remove the cap and then remove the terminal 30/B+ - 1 - nut.
- Disconnect the electrical connector - 2 -.
- Remove the generator - 1 - to the right between the wiring harness - 2 - and the automatic transmission fluid (ATF) lines - 3 - - arrow -, as illustrated.
Installing
• Tightening specification, refer to => [ Generator with Bushings Overview ] Generator With Bushings Overview.
Install in reverse order of removal. Note the following:
• Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque. During removal the bushing may come out a little. During reinstallation ensure that the bushing is fully seated against the bracket before final torque is achieved.
- Drive retaining bolt bushings back slightly for easier generator installation.
- Install the right air guide pipe.
- Place ribbed belt over ribbed belt pulleys.
1. Generator
2. Idler pulley
3. Idler pulley
4. Coolant pump
5. Idler pulley (varies depending on construction version)
6. Power steering pump
7. A/C Compressor
8. Ribbed belt tensioner
9. Vibration damper
• When installing the ribbed belt, make sure it is seated correctly on the belt pulley.
- Connect battery. Required actions, refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.
- Start the engine and make sure the belt it running correctly.