Generator
- 1 - V-belt
- 2 - generator
- 3 - voltage regulator
- 4 - bolts
- 5 - protective cover
- 6 - bolts
- 7 - bolts, 50 Nm
- 8 - bolts, 50 Nm
- 9 - holder
- 10 - tensioner
- 11 - bolts, 45 Nm
Gas engine
Withdrawal
1. Disconnect battery ground cable (–) with the ignition off.
Warning: In this way, data in the electronic memory units, such as the code of the radio receiver, are erased. Without a code, only the manufacturer of the radio can turn on the radio, for example, the radio AUDI STO AUDI. So read the instructions in the subsection Removing and installing the battery.
2. Loosen the mounting bolts and remove the engine cover. To do this, remove the plugs and unscrew the nuts (arrows in the illustration). The illustration shows the 1.6L AEN engine.
3. Mark the direction of rotation of the V-belt. To do this, draw an arrow in the direction of rotation with chalk. The V-belt, viewed from the side of the belt, rotates clockwise.
4. Remove the V-belt, refer to subsection Removing and installing ribbed V-belt.
5. Remove the 3 bolts securing the V-belt tensioner.
6. Disconnect the electrical wire -1- (terminal 30/B+).
7. Disconnect the cable tie -3-.
8. Disconnect the connector -2-, for which press the wire clamp.
9. Turn away bolts of fastening and remove the generator from the holder.
Installation
10. Before installing, drive in the threaded bushings of the mounting bolts at the generator by about 1 mm, (IN).
11. Install the generator on the holder and secure with a torque of 25 Nm.
12. Secure the electrical wires with a torque of 15 Nm and dock. Fasten the cable clamp with a torque of 15 Nm.
13. Fasten the V-belt tensioner with a torque of 25 Nm.
14. Reinstall the V-belt, refer to subsection Removing and installing ribbed V-belt.
15. Install the engine cover and secure it with bolts.
16. Connect ground cable (–) battery.
Warning: Activate the height automatic power window, and also set the clock and enter the radio code, refer to the subsection Removing and installing the battery.
Diesel engine
Withdrawal
17. Disconnect battery ground cable (–) with the ignition off.
Warning: In this way, data in the electronic memory units, such as the code of the radio receiver, are erased. Without a code, only the manufacturer of the radio can turn on the radio, for example, the radio AUDI STO AUDI. So read the instructions in the subsections Removing and installing the battery And Entering the radio code.
18. Remove the engine cover as follows (refer to accompanying illustration):
- Remove plug -1-.
- Remove the nuts (arrows).
- Remove clip -2- from pin -3- and remove cover.
19. Remove the sound absorbing element in the center and on the right.
20. Disconnect the electrical wire -1- (terminal 30/B+), refer to the illustration.
21. Disconnect the cable tie -3-.
22. Disconnect the connector -2-, for which press the wire clamp.
23. Mark the direction of rotation of the V-belt. To do this, draw an arrow in the direction of rotation with chalk. The V-belt, viewed from the side of the belt, rotates clockwise.
24. Remove the V-belt, refer to subsection Removing and installing the V-belt.
25. Remove the 3 bolts securing the V-belt tensioner.
26. Air conditioner: Loosen the mounting bolts (A) and remove the compressor and hang it on the body with the wires attached.
27. Vehicles with enhanced cooling: Remove the additional fan on the right. Protect the radiator from damage with cardboard.
28. All vehicles: Turn away bolts of fastening and remove the generator, take it out upward.
Installation
29. Before installation, drive in the threaded bushings of the mounting bolts at the generator by about 1 mm, see also (IN).
30. Install the generator on the holder and secure with a torque of 25 Nm.
31. Vehicles with enhanced cooling: Install the right additional fan, remove the cardboard.
32. Air conditioner: Fasten the compressor to the holder with a torque of 45 Nm.
33. Fasten the belt tensioner with a torque of 25 Nm.
34. Install the V-belt, refer to subsection Removing and installing the V-belt.
35. Secure the electrical wires with a torque of 15 Nm and join them. Fasten the cable clamp with a torque of 15 Nm.
36. Install the noise damper in the center and on the right.
37. Fasten the engine cover, push in the plugs.
38. Connect ground cable (–) battery.
Warning: Activate the height automatic power window, and also set the clock and enter the radio code, refer to the subsection Removing and installing the battery.
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