Connect a voltmeter to the battery terminals.
While observing the voltmeter reading, start the engine. In starter mode, the voltage can drop to 8 V (at an outside temperature of 20°C).
Increase the engine speed to 3000 rpm, while the voltage should increase to 13.7-14.6 V. This indicates the normal operation of the generator and voltage regulator.
At an engine speed of 3000 rpm, turn on the high beam headlights or other powerful consumers of electricity, while the voltage drop should be no more than 0.4 V.
In case of significant voltage deviations during the test, the generator must be checked in a specialized workshop.
Gas engine
Withdrawal
The removal and installation of a 1.8-1 gasoline engine generator with air conditioning is given.
Remove the wire «masses» with battery.
Attention
- When the battery terminals are disconnected, the data on the recorded malfunctions are erased in the memory blocks of the control devices, therefore, before disconnecting the battery terminals, it is advisable to contact a specialized workshop to recall the malfunctions recorded in it from the memory. After connecting the battery terminal, it is necessary to activate and reprogram the power windows, as well as the position of the rear-view mirrors and seats.
- Also, if a radio with a code is installed in the car, then before disconnecting the terminals from the battery, check that you have the code to reactivate the receiver. Otherwise, it will be possible to put the radio receiver into operation only at a specialized station.
Unscrew, remove from the bracket and move aside the expansion tank together with the hoses connected to it.
Remove air tube 1 (pic. 14.11) connecting the throttle assembly and the charge air cooler.
Remove poly V-belt.
Remove the V-ribbed belt tensioner.
Release two clips 2 (pic. 14.12) and remove holder 1.
Remove from holder 1 (pic. 14.12) wires from the starter and alternator.
Unscrew connecting bracket 1 (pic. 14.13) fixing the air conditioning piping located on top of the torque compensation support.
Unscrew the nuts and disconnect the wires from the terminals «30/B+» And «D +» generator (pic. 14.14).
Unscrew nut 2 (pic. 14.15) top mounting of the generator, holding the bolt 1 from turning. Remove the upper alternator mounting bolt.
Unscrew a bolt of the lower fastening of the generator 3 (pic. 14.15) and remove the generator. When removing the alternator, do not damage the air conditioning piping.
Installation
Installation is carried out in the reverse order of removal, taking into account the following points.
Check that the V-ribbed belt is correctly positioned on the pulleys.
Tighten the lower alternator mounting bolt to 45 Nm.
Tighten the alternator fastening nut to 22 Nm.
Tighten the nuts securing the wires to the terminal «30/B+» torque 16 N·m, to the terminal «D+» - torque 4 Nm.
If the car has a coded radio, reprogram it.
Set the time on the clock.
Activate the power windows.
Differences on 2.4-/2.8-I engines
Remove poly V-belt.
Disconnect air duct 3 (pic. 14.16) on the back of the generator.
Unscrew the nuts and disconnect the wires from the terminals «30/B+» And «D +» generator (pic. 14.16).
TDI engine
Withdrawal
Remove the wire «masses» with battery.
Attention. When the battery terminals are disconnected, the data on the recorded malfunctions are erased in the memory blocks of the control devices, therefore, before disconnecting the battery terminals, it is advisable to contact a specialized workshop to recall the malfunctions recorded in it from the memory. After connecting the battery terminal, it is necessary to activate and reprogram the power windows, as well as the position of the rear-view mirrors and seats.
Also, if a radio with a code is installed in the car, then before disconnecting the terminals from the battery, check that you have the code to reactivate the receiver. Otherwise, it will be possible to put the radio receiver into operation only at a specialized station.
Remove poly V-belt.
Unscrew the nuts and disconnect the wires from the terminals «30/B+» And «D +» generator (pic. 14.17).
Disconnect from the generator an electric socket 3 (pic. 14.17).
Unscrew bolts 1 and 2 (pic. 14.18) and remove the generator. When removing the generator, press the hose of the cooling system to the side and remove the generator upwards.
AFB engine. Disconnect the connector from the engine hydraulic mount and remove the alternator downwards. When removing the alternator, do not damage the air conditioning piping.
Installation
Installation is carried out in the reverse order of removal, taking into account the following points.
AFB engine
Connect the connector to the engine hydraulic mount.
Tighten bolt 1 (pic. 14.18) torque 45 Nm.
Tighten bolt 2 (pic. 14.18) torque 20 Nm.
Tighten the nuts securing the wires to the terminal «30/B+» torque 16 Nm, to terminal «D+» - torque 4 Nm (see fig. 14.17).
If the car has a coded radio, reprogram it.
Set the time on the clock.
Activate the power windows.
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