Alternator: Service and Repair

Generator (GEN) - 3.0L 6-cylinder Engine, Removing And Installing

Special tools, testers and auxiliary items required







- Ribbed Belt Installation Tool 3299 with tensioner claw 3299/1







- VAG 133-Torque wrench (or 5-50 Nm equivalent)

Removing
- Disconnect battery.







- Remove front engine cover - arrows -.

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







- Relieve ribbed belt tension by turning tensioner in direction of - arrow-.
- Remove ribbed belt from power steering pump pulley.
- Lift vehicle.







- Release fasteners - 1 - and - 2 - and remove front noise insulation.







- Remove cable ties - arrows -, unclip cover for starter cable guide harness and remove harness from guide.







Vehicles with automatic transmission:
- Remove nuts - 1 - and - 2 -.
- Remove bracket for ATF lines.

All models:
- Unclip refrigerant line from bracket at sump.
- Disconnect electrical connections at generator.
- Remove bolts - arrows -.







- Remove generator.

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

CAUTION:
- Before installing the ribbed belt, ensure that all subassemblies (generator, ale compressor etc.) are securely mounted and turn freely.
- When installing belt, ensure correct seating in the belt pulleys.
- Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.







- Note running direction of ribbed belt as previously marked and route as illustrated.
1. Generator (GEN)
2. Ribbed belt
3. Power steering pump
4. Air conditioner compressor
5. Crankshaft
6. Tensioning roller

- Reconnect battery. Required steps.
- Start engine and check belt running.

Tightening torques

Component - fastener Nm
Generator to engine bracket - bolts
M8 22
M10 45
Terminal 30/B+ to generator - nut 16
Bracket for refrigerant line to sump - bolt 10
Bracket for starter wire to
engine console - bolt 10