Alternator Pulley / Clutch: Service and Repair

Generator (GEN) Ribbed Belt Pulley - 6-cyl. Engine, Removing And Installing

Special tools, testers and auxiliary items required







- Torque wrench V.A.G 1332/ (or 40 - 200 Nm equivalent)







- Multi-tooth adapter VAS 3400

Removing:
- Clamp generator on bracket points in bench vise.
- Remove protective cap from freewheel pulley.

NOTE: Thread on generator shaft is left-handed. Turn clockwise to loosen. Turn counter-clockwise to tighten.







- Insert Multi-tooth adapter 3400 -1 - with box-end wrench into freewheel pulley - 2 -. Then, insert a Multi-tooth socket insert M 10 - 3 - into generator shaft.
- Loosen threaded connection by rotating clockwise, while counterholding with box-end wrench.
- Hold the freewheel pulley firmly by hand and rotate it on the generator drive shaft until the freewheel pulley can be removed.

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

- First screw overrunning clutch pulley on generator shaft by hand until limit stop.

The torque wrench must be modified for mounting the freewheel pulley as follows:







- Release the insert -1 - and pull it from the handle - 2 -.
- Rotate the handle - 2 - of the torque wrench 180 degrees and re-insert the bit.
- Set the rotation direction of the torque wrench bit to "left."







- Counterhold Multi-tooth adapter 3400 -1 - using ring wrench 17 mm and tighten overrunning clutch pulley by turning generator drive shaft toward left using torque wrench - 2 - (Tightening torque: 80 Nm).
- Clip the protective cap onto freewheel pulley.