Generator (GEN) - 6-cylinder 184kW (250 bhp) engine, removing and installing

CAUTION:

Before beginning repairs on the electrical system:

Obtain the anti-theft radio security code.
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Disconnect negative ( - ) battery terminal.

When disconnecting and reconnecting battery terminals, observe all applicable Notes and torque specifications, as well as instructions on performing OBD program and electrical system function checks as specified in this article. Refer to Battery, disconnecting and reconnecting .

Special tools, testers and auxiliary items needed

Fig 1: Torque Wrench V.A.G 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG 1331 Torque wrench (or equivalent 5 - 50 Nm )

Removing

Disconnect battery. Refer to Battery, disconnecting and reconnecting .

Fig 2: Removing Screw And Coolant Expansion Tank Cover

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Release fastener -1- and remove cover in direction of -arrow-.

CAUTION:

Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.

Fig 3: Screwing Into Bore On Tensioning Element

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Thread M8 x 40 bolt -arrow- into tensioner enough to relieve ribbed belt tension.
Remove ribbed belt.

Fig 4: Removing Upper/Lower Securing Bolt For Generator

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Remove upper bolt -2-.
Lift vehicle.

Fig 5: Identifying Center Sound Insulation Fasteners

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Remove screws -1-, -2- and -3-.
Remove center noise insulation panel.

Fig 6: Right Sound Insulation

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Remove screws -arrows-.
Remove right noise insulation.

Fig 7: Left Sound Insulation Panel

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Remove screws -arrows-.
Remove left noise insulation.

Fig 8: Removing Cross Piece

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Remove bolts -arrows-.
Remove cross brace.

Fig 9: Removing Bolts And Power Steering Pump From Bracket

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Remove bolts -arrows-.
Suspend power steering pump from lock carrier (leave hydraulic hoses -1- and -2- connected).

Fig 10: Disconnecting Electrical Connector For Air Conditioning Compressor Clutch

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Disconnect electrical connector -1-
Remove bolts -arrow-.

CAUTION:

Do not remove refrigerant hoses from a/c compressor.
Have helper carefully lever engine to left when removing bolts. Loosen or remove engine/transmission mountings if necessary.

Suspend a/c compressor from long member (leave refrigerant hoses connected).

Fig 11: Removing Upper/Lower Securing Bolt For Generator

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Remove lower bolt -1-.
Remove generator from bracket (leave wiring connected).

Fig 12: Identifying Connector, Electrical Wire And Wiring Clamp On Generator

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Remove harness retainer -3- at generator.
Remove nut -1- from generator terminal B+ and remove connector eyelet from terminal.
Disconnect electrical connector -2-.
Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:

Engine/transmission mountings that may have been loosened or removed must be adjusted. Refer to 10 ENGINE - ASSEMBLY
Before installing the ribbed belt, make sure that all subassemblies (generator, a/c compressor etc.) are securely mounted and turn freely.
When installing belt, ensure correct seating in the belt pulleys!

Fig 13: Poly V-Belt Routing

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Note running direction of ribbed belt as previously marked and route as illustrated.

Fig 14: Screwing Into Bore On Tensioning Element

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Remove M8 x 40 bolt -arrow- from tensioner.
Reconnect battery. Refer to Battery, disconnecting and reconnecting .
Perform work steps specified in table. Refer to Battery, disconnecting and reconnecting .
Start engine and check belt running.

Tightening torques

Component	Nm
Generator to bracket - bolt	23
Terminal B+ to generator - nut	16
A/C compressor to bracket - bolt	45
Power steering pump to bracket - bolt	23