Generator, 2.0L FSI Turbo

Generator, 2.0L FSI Turbo

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.

- Remove screws - arrows -.





- Disconnect electrical connection - arrow -.





- Loosen spring clamps - arrow - using spring clamp pliers (VAS 5024 A).





- Pull off engine cover upward - arrows -.





• All hose connections for charge air system are secured by spring-type clamps or by connector couplings. The following must be observed with connector couplings:





• Release connection by pulling locking clip - arrow -.

• Disconnect hose/pipe without tools.

- Disconnect connector coupling - arrow -.





- Loosen spring clamp - arrow - using spring clamp pliers (VAS 5024 A).





- Remove screws - arrows -.





- Remove hose from vehicle.

- 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.

- Slacken ribbed belt by pivoting tensioner with an SW 16 open end wrench in - direction of arrow - and secure tensioner using mandrel (T10060 A).





- Remove ribbed belt.

- Loosen bolts of coolant pipe - arrows -.





• The coolant pipe can remain installed. It must be loosened in order to take out the generator.

- Remove generator screws - arrows -.





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





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





- Unscrew wire retainer - arrow - from generator.





- Remove generator from vehicle.

Installing

Install in reverse order of removal, noting the following:

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

• 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!

- 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 9 o'clock position.





• All hose connections for charge air system are secured by spring-type clamps or by connector couplings. The following must be observed with connector couplings:





• Connect hose/pipe without tools.

• Make sure retaining tabs lock securely - arrow -.

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

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.