2.0L TDI

Generator

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Torque Wrench (V.A.G 1332)


Always follow the instructions regarding disconnecting and connecting the battery. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.

Removing

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

- Pull the engine cover upward at the corners - arrows - from the mounting points.






- Move the lock carrier into the service position. Procedures


Mark the top of the ribbed belt and the running direction before removal. Make sure the belt is installed correctly and pay attention to the running direction. If the belt is installed in the opposite running direction or is positioned incorrectly, the belt will fail!

- Remove the ribbed belt.

- Remove the A/C compressor.

• The hoses on the A/C compressor can remain connected.






• Tie the A/C compressor - 3 - to a suitable place under the vehicle using a binding wire - 1 - until it is ready to be reinstalled.

• Make sure the hoses - 2 - are not pulled off or kinked.

- Release and disconnect the (DF lead) - 1 - from the generator.






- Pry off the cover - 2 -.

- Remove the nut - 1 - and then remove the B+ wire from the threaded connector on the generator.






- Remove the nut - 3 - and the wire holder - 2 - from the generator.

- Remove the bolts - 1 - and nuts - 2 - from the fuel filter - 3 - and then move the fuel filter - 3 - to the side. The fuel hoses can remain connected.






- Remove the screws - arrows - from the generator.






- Remove the generator.

Installing

Install in reverse order of removal. Note the following:


• 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/power steering pump) are securely fastened.

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

- Remove the threaded bushings - A - from the generator housing approximately 4 mm in - direction of arrow -.






- Attach the wire holder - arrow - on the back of the generator in the 3 o'clock position.






- Tighten the threaded connections to the tightening specifications. Refer to => [ Generator Overview ] Generator Overview.


Before installing the engine cover, make sure the four fasteners (ball sockets) are positioned correctly. Bring them into the correct position if necessary. Otherwise the engine cover will be damaged.

- Place the engine cover on the mounting points and press the corners into the retainers.

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

- Start the engine and make sure the belt it running correctly.

- Turn off the engine.