Generator (GEN) - 4-cylinder 132kW (180 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 )

Fig 2: Special Tool - T10060

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T10060 Mandrel

Removing

Disconnect battery. Refer to Battery, disconnecting and reconnecting .

Fig 3: Removing Engine Cover Panel

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Remove engine cover -1- and cover in front of intake manifold -2- -arrows-.

Fig 4: Lock Carrier And Battery Covers

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Release fasteners -arrows- and remove left lock carrier cover -1-

Fig 5: Locating Fasteners, Right Lock Carrier Cover And Expansion Tank Cover

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Release fasteners -arrows- and remove right lock carrier cover -1- and expansion tank cover -2-.

CAUTION:

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

Fig 6: Relieving Tension On Poly V-Belt

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Loosen ribbed belt by turning tensioner in direction of -arrow-.

Fig 7: Blocking Tensioner With Mandrel T10060

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Block tensioner with T10060.
Remove ribbed belt.

Fig 8: Secondary Air System Pipe Brackets At Engine

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Remove secondary air system pipe from brackets at engine -arrows-.

Fig 9: Identifying Electrical Change-Over Valve Connector, Intake Manifold Brackets & Dipstick Tube

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Remove bolts -2- and -3-.
Pull off holder from guide tube for dipstick -4-.
On underside of holder, disconnect electrical connections -1-
Disconnect vacuum hose to solenoid valves at intake manifold.

Set aside holder with connected hoses.
Pull air hoses off of secondary air pump.

Fig 10: Generator Electrical Connector And Terminal B+

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

Fig 11: Generator Mounting Bolts

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Remove bolts -arrows-.
Lift generator from bracket and up to left of engine compartment.

Installing

Install in reverse order of removal, noting the following:

Press sleeves into generator mounting to aid in installation.

CAUTION:

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 12: Identifying Belt Drive For Vehicles With Air Conditioning

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Note running direction of ribbed belt as previously marked and route as illustrated.
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
Secondary air pipe bracket to manifold - bolt	10
Secondary air pipe to bracket - bolt	10