27-101

Generator (GEN) - 4-cylinder TDI engines 4-cylinder TDI engines with power steering through 04.99, assembly

1 - Hex bolts

M8 x 45mm

25 Nm

2 - Tensioner

3 - Bracket

4 - Hex bolt

M10 x 45mm

45 Nm

5 - Hex bolts

M10 x 65mm

45 Nm

6 - Hex bolts

M3 x 18mm

7 - Protective cap

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27-102

8 - Screws

M4 x 25mm

9 - Voltage Regulator (VR)

Removing and installing

Items 6 , 7, 8

Checking carbon brushes

Page 27-75

10 - Generator (GEN)

Tightening torque B+ wire to generator

Page 27-72

11 - Ribbed belt

Removing and installing

Page 27-109

Ribbed belt routing

Page 27-113

12 - Hex bolts

M8 x

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85mm

25 Nm

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27-103

4-cylinder TDI engines with power steering from 05.99, assembly

1 - Hex socket bolts

M8 x 45mm

25 Nm

2 - Tensioner

3 - Bracket

4 - Hex bolt

M10 x 45mm

45 Nm

5 - Hex bolts

M10 x 65mm

45 Nm

6 - Screws

7 - Nut

M8

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27-104

8 - Nut

M8

9 - Screw

10 - Voltage Regulator (VR)

Removing and installing

Page 27-78

Checking carbon brushes

Page 27-79

11 - Protective cap

12 - Generator (GEN)

Tightening torque B+ wire to generator

Page 27-77

13 - Ribbed belt

Removing and installing

Page 27-109

Ribbed belt routing

Page 27-113

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14 - Hex bolts

M8 x 85mm

25 Nm

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27-105

4-cylinder TDI engine with power steering and A/C compressor through 04.99, assembly

1 - Tensioner

2 - Bracket

3 - Hex bolt

M10 x 45mm

45 Nm

4 - Hex bolts

M10 x 65mm

45 Nm

5 - Relay roller

6 - Hex bolt

M8 x 50mm

25 Nm

7 - Relay roller protective cap

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27-106

8 - Hex bolts

M3 x 18mm

9 - Protective cap

10 - Screws

M4 x 25mm

11 - Voltage Regulator (VR)

Removing and installing

Items 8, 9, 10

Checking carbon brushes

Page 27-75

12 - Generator (GEN)

Tightening torque of B+ wire to generator

Page 27-72

13 - Ribbed belt

Removing and installing

Page 27-109

Ribbed

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belt routing

Page 27-113

14 - Hex bolts

M8 x 85mm

25 Nm

15 - Hex bolts

M8 x 45mm

25 Nm

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27-107

4-cylinder TDI engine with power steering and A/C compressorfrom 05.99, assembly

1 - Tensioner

2 - Bracket

3 - Hex bolt

M10 x 45mm

45 Nm

4 - Hex bolts

M10 x 65mm

45 Nm

5 - Relay roller

6 - Hex bolt

M8 x 50mm

25 Nm

7 - Relay roller protective cap

8 - Screws

9 - Nut

M8

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27-108

10 - Nut

M8

11 - Screw

12 - Voltage Regulator (VR)

Removing and installing

Page 27-78

Checking carbon brushes

Page 27-79

13 - Protective cap

14 - Generator (GEN)

Tightening torque of B+ wire to generator

Page 27-77

15 - Ribbed belt

Removing and installing

Page 27-109

Ribbed belt routing

Page 27-113

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16 - Hex bolts

M8 x 85mm

25 Nm

17 - Hex bolts

M8 x 45mm

25 Nm

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27-109

Ribbed belt, removing and installing

CAUTION!

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

Check ribbed belt Page 27-81 . Always replace ribbed belt if found to be faulty. Twill avoid related failures or operating problems.

Special tools and auxiliary items needed

Bolt - M8 X 50

Removing

- Lift vehicle.

- Remove bolts -arrows- and remove center sound insulation.

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27-110

- Remove nut, release clips -arrows- and remove right noise noise insulation.

- Remove caps -arrows- on engine cover -A-.

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27-111

Repair Manual, 1.9 Liter 4-Cyl. 2V TDI Engine Mechanical, Engine Code(s): ALH, Repair Group 21

- Release nuts -arrows-.

- Lift engine cover -A- from engine.

- Remove charge air pipe between charge air cooler and exhaust turbocharger.

- Mark direction of rotation of ribbed belt if it is to be reused.

Note:

Remove ribbed belt from idler roller first.

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

- Remove ribbed belt.

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27-112

Installing

CAUTION!

Note previously marked running directionribbed belt when reinstalling.

Before installing ribbed belt, make sure thall subassemblies (generator, a/c compressor, etc.) are securely mounted aturn freely.

When installing belt, ensure correct seatiin the belt pulleys!

- Turn tensioner in direction of -arrow-.

- Install ribbed belt according to routing diagra Page 27-113 .

- Install charge air pipe.

- Start engine and check belt running.

- Install engine cover.

- Install center and right sound insulation.

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27-113

Ribbed belt, routing

4-cylinder TDI engine with power steering pump

1 - Pulley - crankshaft/vibration damper

2 - Tensioning roller

3 - Pulley - generator

4 - Ribbed belt - crankshaft/vibration damper, tensioning roller, generator and power steering vane pump

5 - Pulley - power steering pump

4-cylinder TDI engine with power steering pump and A/C compressor

1 - Pulley - power steering pump

2 - Ribbed belt - power steering pump, idler roller, a/c compressor, crankshaft/vibration damper, tensioning roller and generator

3 - Idler roller

4 - Pulley - a/c compressor

5 - Pulley - crankshaft/vibration damper

6 - Tensioning roller

7 - Pulley - generator

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