Generator (GEN) - 4-cylinder 165kW (225 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

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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/Installing Engine Cover

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Release fasteners -arrows- and remove engine cover.

Fig 4: Cover In Front Of Intake Manifold

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Remove cover in front of intake manifold -arrows-.

Fig 5: Removing Left-Hand Cover Panels On Lock Carrier And Battery

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

Fig 6: Removing Covers At Lock Carrier And Above Coolant Expansion Tank

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

Fig 7: Removing Intake Air Duct

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Release hose clamps and fasteners -arrows- and remove air pipe.

Fig 8: Vacuum Pipe And Coolant Hose

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Release hose clamps and remove vacuum pipe -2- from intake manifold.

NOTE: Disregard coolant hose -1-.

Fig 9: Locating Electrical Connector

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Where applicable, disconnect electrical connector -arrow-.

Fig 10: Disconnecting Electric Harness Connector At Exhaust Gas Temperature (EGT) Sensor 1 -G235-

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Where applicable, disconnect electrical connector -arrow-.

Fig 11: Holder, Bolts And Coolant Hose

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Remove bolts -2- and -3-.
Pull holder -4- off guide tube for dipstick.
Disengage coolant hose -1- from holder.
Set aside holder with hoses connected.

CAUTION:

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

Fig 12: Relieving Tension On Poly V-Belt

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

Fig 13: Blocking Tensioner With Mandrel T10060

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Block tensioner with T10060.
Remove ribbed belt.

Fig 14: 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 15: 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 16: 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