Generator, 2.5L

Generator, 2.5L

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.

- Release and disconnect the connectors - 1 - and - 2 -.





- Loosen spring clamp - 3 - and remove air hose.

- Remove both bolts - arrows -.

- Pull engine cover with air filter upward - arrows - and remove from vehicle.





- Remove noise insulation

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!

- Remove ribbed belt

- Release and disconnect connector - 1 - and remove air conditioning compressor bolt - 2 -.





- Remove both remaining bolts - arrows - and remove the air conditioning compressor from the sub-assembly bracket.





• Make sure that both centering sleeves are not lost.

• Hoses on A/C compressor can remain connected.





• Tie A/C compressor - 2 - to an suitable place under the vehicle using bundling wire - 1 - until it is ready to be reinstalled.

• Make sure that connected hoses are not pulled off or kinked.

- Remove both bolts - arrows - and remove lower idler pulley - 1 - from the sub-assembly bracket.





- Remove the three mounting bolts - arrows - and the upper idler pulley - 1 - from the sub-assembly bracket.





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





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





• To obtain easier access to the generator bolts, remove Drift (T10060 A) and release tension at upper generator and coolant pump ribbed belt tensioner => [ ] Ribbed Belt, Routing, 2.5L.

- Remove upper generator bolt - arrow -.





- Remove the lower generator bolt - arrow - and the generator from the sub-assembly bracket. Be careful of the connected lines.





- Remove harness retainer from generator - arrow -.





- Remove generator downward from vehicle.

Installing

Install in reverse order of removal, noting the following:

CAUTION!
• 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!

• Before assembling the air conditioning compressor, make sure both centering sleeves are inserted in the sub-assembly bracket threaded holes.

- 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.





- Tighten the threaded connections to the specification given in the assembly overview. Refer to=> [ Generator Assembly Overview, 2.5L ] Generator Assembly Overview, 2.5L.

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.