Independent dismantling and installation of the generator is not such a simple matter. The volume of this complex work is determined by the design of the generator holder and the method of dismantling the V-ribbed belt. Dismantling is fundamentally different in vehicles with four- and six-cylinder engines.
Vehicles with a four-cylinder engine
1. Dismantling: Open the cap of the coolant expansion tank. Since hot steam may come out when you open the lid, cover the lid with a cloth, then carefully open the lid.
2. Remove the engine cover. On vehicles with an independent heater, on the soundproof cover, unscrew the three screws securing the heater pipe.
3. Remove the soundproof cover by loosening it at ten points. Substitute a tray under the engine to collect fluid (V.A.G. 1306).
4. Remove retaining clip 1 and remove coolant temperature sensor (G2) 2
Retaining clip 1 and coolant temperature sensor 2
5. Drain the coolant from the radiator only. After that, remove the hose from the cooling system pipe (arrow).
Hose on the cooling system pipe. The hose is removed in the place indicated by the arrow
6. Unscrew the radiator fan control (arrow), remove it and set it aside.
fixing screw (arrow) on the control unit for the radiator fan
7. Turn the poly V-belt tensioner in the direction of the arrow to loosen the belt.
The poly V-belt tensioner must be turned in the direction of the arrow
8. Remove the V-ribbed belt from the alternator pulley and loosen the tensioner.
9. Disconnect connector 1, and in the case of a 2.0 liter engine, also connectors 2 and 3.
10. Turn out 4 fixing screws and remove the generator. Unscrew terminal D+.
Plug connections on the generator: 1 and also (in case of 2.0L engine) 2iZ
The arrows show the top and bottom mounting screws of the generator
11. Installation is carried out in the reverse order. Be sure to pay attention to the accuracy of fit and the passage of the V-ribbed belt.
When mounting the generator, pay attention to the accuracy of fit and the passage of the V-ribbed belt
12. Fill in the coolant, when connecting the battery, do not forget to activate the corresponding devices.
Vehicles with a 6-cylinder engine
1. Dismantling: Remove the engine top cover at an angle upwards. Open the V-ribbed belt. Before removing the belt, mark the direction of the belt movement with chalk or felt-tip pen. If the old belt is installed in the opposite direction, it may fail.
2. To loosen the belt, turn the tensioner in the direction of the arrow (3299, 3299/1).
The poly V-belt tensioner must be turned in the direction of the arrow
3. Remove the belt from the steering pump pulley. In the case of a vehicle with an independent heater, unscrew the three heater pipe screws on the cover of the soundproof cover. Remove the soundproof cover by loosening it at ten points.
4. Disconnect both cable ties at the points indicated by the arrows. Open the intake manifold holder and remove the electrical wire.
Disconnect the cable ties at the points indicated by the arrows
5. In cars with an automatic transmission remove the holder for pipelines for a working liquid. To do this, unscrew nuts 1 and 2.
In cars with automatic transmission, remove the holder for pipelines for working fluid, to do this, unscrew nuts 1 and 2
6. Remove the wires from the generator (see step 9 for 4-cylinder engines). Turn out fixing screws and remove the generator.
The arrows show the mounting screws of the generator
7. Installation is carried out in the reverse order. Pay special attention to the accuracy of fit and the passage of the V-ribbed belt.
Passage of the V-ribbed belt: 1 - generator, 2 - V-ribbed belt, 3 - vane pump for steering servo, 4 - air conditioning compressor, 5 - crankshaft, 6 - tension roller.
8. Tightening torques during installation: generator to engine: M8 - 22 Nm, M10 - 45 Nm, terminal 30 / V + on the generator - 16 Nm, terminal on the battery pole - 6 Nm. Start the engine and check the belt passage. After connecting the battery, activate the corresponding devices.
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