Table of contents: Overview of generator installation… ↓ Removal and installation the… ↓ Removal and installation the… ↓
Overview of generator installation with sliding bushings
1. Bolts: 23 Nm.
2. Generator.
3. Bushing: Since tight bushings have low clamping force despite the correct tightening torque, the bushings need to be designed.
4. Electrical plug connection.
5. Nut: 16 Nm.
6. Plug.
7. Terminal 30/AKB+.
Removal and installation the generator - vehicles with a 2.0L TDI engine
Remove the engine cover.
Remove the timing belt protective cover by releasing the "arrow" clamps.
Turn the tensioner to loosen the poly V-belt tensioner in the direction of the arrow. Remove the poly V-belt from the alternator pulley. Secure the tensioner with the T40098 clamp.
Loosen hose clamp "2" and remove air duct hose "3" on throttle body "J338". Unscrew bolt "1".
Unscrew nut "3" and disconnect connector "1". Remove the coolant pump "V51" "pos. 2" with the bracket and set it aside with the coolant hoses connected.
Unscrew the double bolt "2" and remove the system pipe. cooling "1" with coolant hoses connected in the "direction of the arrow".
Unscrew terminal 30/B+ "pos. 1". Disconnect plug connection "2".
Remove the "arrow" bolts. If the bolts cannot be removed, push the fan frame forward slightly. If the generator is clamped in the bracket, tighten the mounting bolts 2 turns again. Gently tap the bolt heads with the flat side of a hammer to release the generator mounting bushings. Remove generator "1", to do this, move the system pipe away. cooling to the side.
Installation
Installation in reverse order. To make installation of the generator easier, move the mounting bolts back a little on the bushings. The movement of the generator mounting bushings must be facilitated, since otherwise the clamping force of the bushing, despite the corresponding torque, is too low. Place the poly V-belt on the poly V-belt pulleys.
1. Vibration damper.
2. Air conditioning compressor. installations.
3. Impeller pump of the steering hydraulic system.
4. Intermediate roller.
5. Tension element.
6. Generator.
Connect the battery. Start the engine and check the belt operation.
Removal and installation the generator - vehicles with 2.7L and 3.0L TDI engines with independent heating
Disconnect the ground wire from the battery with the ignition off. Remove the engine cover.
Remove the "arrow" air duct.
Disconnect connector "1" from the air flow meter "G70". Unscrew bolt "3" and release exhaust gas pressure sensor 1 "G450" "pos. 4" from the air duct pipe. Loosely place connector "2" for the temperature sensor after the particulate filter "G527" on the air duct. Remove the air duct hose with the air flow meter "G70" by loosening the hose clamp "5" and opening the clamping clamps "arrows".
Disconnect vacuum line "1". Remove the lower part of the air. filter and disconnect it at the back. side connector "2" on the air bypass damper valve. filter "N275".
Remove the front wall of the water drainage box. Unscrew bolts "2" and "3". Remove the air duct tube from the air duct hose by loosening clamp "1" of the hose.
Compress coolant hoses "1" and "2" with clamps up to 25 mm "3094".
Remove the right front. wheel. Loosen the front part of the front fender liner. right wheel arch and press back. Remove the front sound insulation by loosening fasteners "1" and "2". Ignore "Pos. 3, 4".
Loosen nut "1" on the silent block. Loosen nut "3" on clamp and remove downpipe "2" from the muffler.
Unscrew bolt "1" and nut "3". Remove spacer "2" from the radiator frame on the right.
Unscrew screws "2". Unscrew screw "4", disconnect and remove clamp bracket "3". Remove the holder of the circulation pump "V55" "pos. 1".
Cars with oil cooler: unscrew the "arrow" bolt of the ATF lines.
Clamp the system hose. cooling "2" hose clamps up to 25 mm "3094". Remove the system hose. cooling from coolant pipe "1".
Loosen nut "1" on the wiring holder a few turns. "Pos. 2" should not be taken into account.
Disconnect the air duct hose from the air duct on the right and set it aside by loosening the "arrow" clamp.
To loosen the poly V-belt, turn the tensioner in the direction of the arrow using a TORX 60 "T40087" socket. Remove the poly V-belt from the alternator pulley.
Loosen the generator's "arrow" bolts approximately 6 turns. Gently tap the bolt heads with a hammer to disengage the generator mounting bushings. Unscrew the bolts completely.
Disconnect the radiator fan connector "1" by moving the locking tab back "arrow" and pressing the stopper down. Release the wire so as not to damage it when removing the generator.
Remove the generator from the bracket. Unscrew terminal 30/V+ "pos. 1". Disconnect plug connection "2". Remove the generator to the right.
Installation
Installation in reverse order. The movement of the generator mounting bushings must be facilitated, since otherwise the clamping force of the bushing, despite the corresponding torque, is too low. To facilitate installation of the generator, move the mounting bolt bushings back a little. Install the V55 circulation pump bracket. Install the V55 circulation pump. Vehicles with an oil cooler: secure the ATF lines. Install the air duct tube on the right. Install the front wall of the water drainage box. Add coolant. Place the poly V-belt on the poly V-belt pulleys.
1. Generator.
2/3. Intermediate roller.
4. Water pump.
5. Intermediate roller (depending on the model).
6. Impeller pump of the steering hydraulic system.
7. Air conditioning compressor, installations.
8. Poly V-belt tensioner.
9. Crankshaft.
Connect the battery. Start the engine and check the belt operation.