Generator, FSI Turbo Engine

Generator, 2.0 L FSI Turbo Engine

Assembly overview







1 - Collar bolts
- M8x45
- 23 Nm
2 - Collar bolts
- M8x90
- 23 Nm
3 - Bracket
- For generator and A/C compressor
- Tightening sequence
4 - Collar bolts
- M10x45
- 45 Nm
5 - Protective cap
6 - Hex head collar nut
- M8
7 - Phillips head screw
- M5x21
- 4.5 Nm
8 - Flat hex nut
- M8
9 - Washer
- M5
10 - Phillips head screws
- M4x19
- 2 Nm
11 - Phillips head screw
- M4x13
- 2 Nm
12 - Voltage regulator voltage regulator
13 - Generator
- Generator, removing and installing
14 - Ribbed belt
15 - Tensioner for ribbed belt

Generator (GEN) - 2.0L TFSI engine, removing and installing

Special tools, testers and auxiliary items required







- Torque wrench V.A.G 1331







- Mandrel T10060 A

Removing:
- Disconnect battery.







- Remove screws -arrows-.







- Open mounting clips -1- and pull hose -2- out of air filter housing.
- Disconnect electrical connection -3-.







- Pull off engine cover upward -arrows-.

CAUTION: Before removing ribbed belt, mark the top side and direction of travel. When installing, pay attention to correct running direction and installation position. If the belt is installed in the opposite running direction or is positioned incorrectly, the belt will fail.

- Mark running direction of ribbed belt.







- Release tension on ribbed belt by swinging tensioning element using a 16 mm open-end wrench in -direction of arrow-.







- Lock tensioner using mandrel T10060 A.
- Remove ribbed belt.







- Loosen bolts of coolant pipe -arrows-.

NOTE: Coolant hose can remain installed. It must be loosened in order to take out the generator.







- Remove generator screws -arrows-.







- Separate the connector for the DF-lead -1- and remove the protective cap -2-.







- Remove the B+ lead -arrow- from the generator.







- Unscrew wire retainer -arrow- from generator.
- Remove generator from vehicle.

Installing:
Install in reverse order of removal, noting the following:

CAUTION:
- When installing an already used ribbed belt, note direction of travel marked when it was removed.
- Before installing the ribbed belt, make sure all components (generator, A/C compressor) are securely fastened.
- When installing the ribbed belt, make sure it is properly seated in the belt pulley.







- Drive threaded sleeves -A- out of generator housing approx. 4 mm in -direction of arrow-.







- Screw wire retainer -arrow- firmly to rear side of generator in 9 o'clock position.
- Tighten all threaded connections using the specified torques.

CAUTION: Observe notes for threaded connections of battery terminals.

- Reconnect battery.
- Start the engine and verify that the belt is running properly.
- Turn off the engine.

Ribbed belt routing, 2.0 L FSI turbo engine







Vehicles without A/C system:
1. Tension roller
2. Belt pulley - generator
3. Ribbed belt
4. Belt pulley - crankshaft







Vehicles with A/C system:
1. Tension roller
2. Belt pulley - generator
3. Ribbed belt pulley - A/C compressor
4. Ribbed belt
5. Belt pulley - crankshaft