3.2L

Generator, Air Cooled

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Bolt M8 x 50 (commercially available - pressure bolt for ribbed belt tensioner)

Removal


When disconnecting battery, procedure must always be followed as described in => [ Disconnecting Sequence ] One-Battery Layout with Auxiliary Battery and Two Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

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

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






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







Mark the top of the ribbed belt and the running direction before removing it. Make sure the belt is installed correctly and pay attention to the running direction. The belt will fail if it installed opposite the running direction or if is installed incorrectly.

- Remove air guides above cooler.

- Install pressure bolt M8×50 - arrow - in tensioner threaded bore until ribbed belt can be removed.







Tensioner housing may be damaged.

If hex bolt is threaded too far into tensioner housing, the housing may be damaged.

Only screw the bolt in so far until the ribbed belt can be removed.

- Remove bolts for tensioner - arrows -.






- Remove the ribbed belt together with the tensioner.

- Remove generator mounting bolts M8 x 90 - arrows -.






Installation


• When installing an already used ribbed belt, note direction of travel marked when it was removed!

• Before installing the ribbed belt, make sure all drive accessories (generator, air conditioner compressor, power steering pump) are secured in place.

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

• Make sure that the pressure bolt M8x50 has been removed from tensioner.

Install in reverse order of removal. Note the following:

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







• When connecting battery, always perform work procedure as described in => [ Connecting Sequence ] One-Battery Layout with Auxiliary Battery and Two Battery Layout, Disconnecting and Connecting. Not adhering to sequence will result in the deactivation of Main Battery Switch -E74- and subsequent damage to electrical system components.

• Observe notes for threaded connections of battery terminals. Refer to => [ Battery Post/Terminal ] Battery Post/Terminal.

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

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

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