Vehicles With 3.0L TDI, Air Cooled Generator

Special tools and workshop equipment required

Torx® Socket - T60 T40087

Removal

Fig 1: Identifying Engine Cover -Arrows-

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NOTE:

When Installation, reinstall all cable ties that were loosened or cut during removal in the same locations.

-- With the ignition switched off, disconnect the battery ground (GND) wire, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Carefully remove engine cover successively from the 4 locking bolts -arrows-.

Fig 2: Rotating Tensioner In -Direction Of Arrow- Using Torx(R) Socket T60 T40087

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CAUTION:

Risk of destroying if the running direction of a used ribbed belt is reversed.

Before Removal ribbed belt, marking running direction with chalk or a felt-tip pen for reinstallation.

-- To release the tension the ribbed belt, move the tensioner in direction of -arrow- using the Torx® Socket - T60 T40087.

-- Remove ribbed belt from tensioning roller.

-- Remove right front wheel.

Fig 3: Identifying Front/Rear Noise Insulation

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-- Remove screws and remove the noise insulation in the front -1- and in the rear -2-.

-- Remove stabilizer bar, refer to STABILIZER BAR, REMOVING AND INSTALLING .

-- Remove the screw -arrow- and move the Fuel Cooler Pump -V166- with coolant hoses and electrical connector still connected to the side.

Fig 4: Identifying Fuel Cooler Pump Screw -Arrow-

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-- Detach wiring harnesses -1- and -2- from generator.

-- Free up electrical wiring harness.

Fig 5: Identifying Wiring Harnesses

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NOTE:

If alternator sticks in holder, install screw again down as far as the last 2 turns.

Carefully strike on bolt heads using flat side of hammer - doing this loosens sleeves of generator mount.

-- Remove the bolts -arrows- and remove generator.

Fig 6: Identifying Generator Bolts -Arrows-

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Installation

Install in reverse order of removal. Note the following:

NOTE:

Replace self-locking nuts.

-- Slightly drive back sleeves for retaining bolts in order for easier installation of generator.

NOTE:

Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.

-- Install stabilizer bar, refer to STABILIZER BAR, REMOVING AND INSTALLING .

-- Fit poly V-belt over pulleys.

Fig 7: Identifying Ribbed Belt Components With An Additional Idler Pulley (3.0L TDI)

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Generator
Idler pulley
Idler pulley
Coolant pump
Idler pulley
Vane pump
A/C Compressor
Tensioner for ribbed belt
Vibration damper

NOTE:

When Installation ribbed belt, be sure that it is seated correctly on belt pulleys.

-- Connect battery. Required actions, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Start the engine and verify that the belt is running properly.

Tightening Specifications:

Component	Nm
Generator to engine	22
Terminal 30/B+ to generator	16
After-Run Coolant Pump -V51- bracket to longitudinal member	22