Generator, 2.0L FSI

Generator, 2.0L FSI

CAUTION!
When disconnecting and connecting battery, the procedure must be followed as described in the repair information. Refer to=> [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Mandrel (T10060 A)

• Spring-type clip pliers (VAS 5024 A)

Removing

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

- Pull off engine cover upward - arrows -.





- Disconnect electrical connection - arrow -.





- Unclip vacuum hose from its retainer - arrow -.





- Disengage spring-type clamp - arrow - from hose - 1 - using Spring Type Clip Pliers VAS5024a (VAS 5024 A).





- Disconnect hose - 1 - from air filter housing.

- Open bracket - arrow - at front side of air filter housing and remove line - 1 -.





- Remove air filter housing mounting bolt - arrow -.





- Pull air filter housing upwards out of right rubber mounting - arrow -.





- Remove spring-type clamp - 1 - using hose clamp pliers (VAS 5024 A).





- Disconnect hose - 2 - from connection.

- Carefully lift air filter housing upward out of vehicle, while paying attention to the line lengths.

- Disconnect harness connector - arrow - on rear side of air filter housing.





- Remove air filter housing from vehicle.

- Remove upper coolant pipe

- Separate the connector for the DF-lead - 1 - and remove the protective cap - 2 -.





- Remove the B+ lead - arrow - from the generator.





- Remove EVAP canister - 1 - upward from catches - arrows -.





- Lay aside EVAP canister - 1 - with hoses connected.

CAUTION!
Before removing ribbed belt, mark the top side and direction of travel. When installing, pay attention to correct running direction and installation position. If the belt is installed in the opposite running direction or is positioned incorrectly, the belt will fail!

- Mark running direction of ribbed belt.

- Release tension on ribbed belt by swinging tensioning element using a 16 mm open-end wrench in direction of - arrow -.





- Lock tensioner using mandrel (T10060 A).





- Remove ribbed belt.

- Remove mounting bolts for tensioning element - arrows -.





- Remove tensioning element together with lifting eyelet - 1 - from vehicle.

- Remove generator screws - arrows -.





- Unscrew wire retainer - arrow - from generator.





- Remove generator from vehicle.

Installing

Install in reverse order of removal, noting the following:

- Drive threaded sleeves - A - out of generator housing approximately 4 mm in - direction of arrow -.





- Screw wire retainer - arrow - firmly to rear side of generator in 12 o'clock position.





- Tighten the threaded connections to the specification given in the assembly overview. Refer to=> [ Generator Assembly Overview, 2.0L FSI ] Generator Assembly Overview, 2.0L FSI.

CAUTION!
• Always follow the sub-assembly bracket tightening sequence to prevent damage to the cylinder block and bracket => [ Sub-Assembly Bracket, Tightening Sequence, 2.0L FSI ] Sub-Assembly Bracket, Tightening Sequence, 2.0L FSI.

• 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) are securely fastened.

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

CAUTION!
Observe notes for threaded connections of battery terminals.

- Reconnect battery. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

- Start the engine and verify that the belt is running properly.

- Turn off the engine.