Removal
Instructions. Below is a description of the work procedure for a car with air conditioning. On a car with the Telematik system, before disconnecting the battery, activate the service mode of the Teiematik control unit - Radio, telephone, navigation.
Disconnect the battery ground wire with the ignition off. Wash the hood outside and wipe with chamois leather. Unlock the service cover from the inside. Unlock the hood "arrows" and pull it forward a little. Pull the hood cover "VAS 6011" onto the hood.
Remove the hood.
Remove the electromagnetic valve 1 of the absorber "N80" "pos. 1" with the holder from the air duct. Remove the air duct "2", for this purpose loosen the spring clamps using pliers for clamping the hoses "V.A.G 1921". Remove the air duct.
Unscrew bolts "2". Remove water trap "3" in the "direction of the arrow". Disconnect air duct hose "6" for heating the air at the intake from the warm air shield. Unscrew bolt "5" on the intake air heater "4". Disconnect hose "1" from the shelf of the lock and the air casing. Mark the direction of rotation of the poly V-belt with chalk or a felt-tip pen. Changing the direction of the previously used belt may damage it.
To loosen the tension of the poly V-belt, turn the tensioner in the direction of the "arrow" with a ring spanner. Fix the poly V-belt tensioner with the help of the mandrel "T10060 A" in the holes. Remove the poly V-belt.
Unscrew the wire of terminal 30/B+ "pos. 1" from the generator. Disconnect connector "2".
Unscrew the generator mounting bolts "1" and "2".
Unlock the fastening brackets "arrows" and remove the toothed belt cover "1". Remove the generator in an upward direction.
If the alternator is clamped in the bracket, tighten the mounting bolts 2 turns again. Gently tap the flat surface of the hammer on the bolt heads to release the alternator mounting bushings.
Installation
Installation in reverse order, taking into account the following: to facilitate installation of the generator, move the mounting bolts back a little. This should facilitate the movement of the generator mounting bushings, since otherwise the clamping force of the bushing, despite the corresponding torque, is too small. Pay attention to the correct fit and movement of the poly V-belt.
Poly V-belt running in a car with an air conditioning system
1. Crankshaft belt pulley
2. Tension roller
3. Generator belt pulley
4. Air conditioning compressor pulley
5. Poly V-belt
Place the poly V-belt on the crankshaft and alternator pulleys. Install the poly V-belt on the air conditioner compressor pulleys last. Unload the tensioner and remove the T10060 A mandrel from the holes. Check that the poly V-belt is installed correctly. Connect the battery. Start the engine and check the belt movement.
Tightening torques:
- Generator to holder: 25 Nm
- Terminal 30/V + to generator: 16 Nm
- Air heater at the inlet to the shelf of the lock: 3.5 Nm
- Air duct hose to the lock shelf: 2.5 Nm