4-cylinder gasoline engines from 05



4-cylinder gasoline engines from 05.99, assembly[pic]

Fig. 77: Exploded View Of 4-Cylinder Gasoline Engine Generator (From 05.99)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Tensioner

2 - Bracket

3 - Hex socket bolts

M10 x 45mm

45 Nm

4 - Screws

5 - Nut

M8

6 - Nut

M8

7 - Screw

8 - Voltage Regulator (VR)

Removing and installing. Refer to Voltage Regulator (VR), removing and installing

Checking carbon brushes. Refer to Generator (GEN) carbon brushes, checking

Fig. 78: Exploded View Of 4-Cylinder Gasoline Engine Generator (From 05.99)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

9 - Protective cap

10 - Generator (GEN)

Tightening torque of B+ wire to generator. Refer to Generator (GEN) B+ & D+ connections, securing

11 - Ribbed belt

Removing and installing. Refer to Ribbed belt, removing and installing

|Location / Fastener |  |Tightening torque |

|Generator B+ (1) terminal / nut |M8 |15 Nm |

|Generator D+ terminal / nut |M5 |3 Nm |

|Generator to bracket / bolt |M8 X 85 |25 Nm |

|Generator pulley without freewheel / nut |  |65 Nm |

|Generator pulley with freewheel / nut |  |80 Nm |

4-cylinder gasoline engines, tightening torques[pic]

|Location / Fastener |  |Tightening torque |

|Bracket to engine block / bolts |M10 |45 Nm |

|Tensioner to engine block / bolts |M8 |25 Nm |

Ribbed belt routing. Refer to Ribbed belt routing

12 - Hex bolts

M8 x 85mm

25 Nm

13 - Hex bolts

M8 x 45mm

25 Nm

Ribbed belt, removing and installing[pic]

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

| |Check ribbed belt. Refer to Ribbed belt, checking . Always replace ribbed belt if found to be faulty. This will avoid related|

| |failures or operating problems. |

Special tools and auxiliary items needed

Fig. 79: Special Tool - T10060

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mandrel T10060 (or equivalent)

Removing[pic]

Lift vehicle.

Fig. 80: Engine Compartment Noise Insulation Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts -arrows- and remove middle lower engine cover (noise insulation).

Fig. 81: Noise Insulation Clips

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove nut, release clips -arrows- and remove right lower engine cover (noise insulation).

2.0L 4-cylinder gasoline engine:

|NOTE: |European market 1.8L engine illustrated here. Engine cover on USA/CDN 2.0L engines is similar. |

Fig. 82: Engine Cover Nuts (2.0L 4-Cylinder Gasoline Engine)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release nuts -arrows- and lift engine cover -A- from engine.

1.8L turbo 4-cylinder gasoline engine:

Fig. 83: Engine Cover Screws (1.8L Turbo 4-Cylinder Gasoline Engine)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release screws -arrows- and lift engine cover from engine.

All gasoline engines, continued:

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

Fig. 84: Turning Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Fig. 85: Blocking Tensioner With Mandrel T10060

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Block tensioner with mandrel T10060 (or equivalent).

Remove ribbed belt.

Installing[pic]

|CAUTION: |Note previously marked running direction of ribbed belt when reinstalling. |

| |Before installing ribbed belt, make sure that all subassemblies (generator, a/c compressor, etc.) are securely mounted and |

| |turn freely. |

| |When installing belt, ensure correct seating in the belt pulleys! |

Install ribbed belt according to routing diagram. Refer to Ribbed belt routing .

Remove mandrel.

Start engine and check belt running.

Install engine cover.

Install center and right (lower) engine covers (noise insulation).

Ribbed belt routing[pic]

Fig. 86: Ribbed Belt Routing (4-Cylinder Gasoline Engine)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

1 - Tensioning roller

2 - Pulley - generator (GEN)

3 - Pulley - a/c compressor

4 - Ribbed belt - generator, a/c compressor, power steering pump and crankshaft/vibration damper

5 - Pulley - power steering pump

6 - Pulley - crankshaft/vibration damper

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Proper Charging Voltage would be;

A. 12.5 – 13.6 V

B. 13.5 – 15.5 V

C. 14.5 – 16 V

D. 15.5 – 17.2 V

The Stationary Component is the;

A. Slip Rings

B. Rotor

C. Fan

D. Stator

The Moving Component is the;

A. Regulator

B. Rotor

C. Brushes

D. Stator

Current is sent into the _____________ from the regulator; this can increase or decrease the output of the _______________

A. Bearings, Case

B. Stator, Brushes

C. Rotor, Stator

D. Stator, Rotor

The _________ allows contact between the rotor and the regular and battery;

A. Bearings

B. Case Mount

C. Brushes

D. Stator

The pulley must:

A. Have the correct number of grooves

B. Be loose

C. Be not aligned with the other accessory drive units

D. Be press fit

The drive belt must be;

A. Have the correct number of grooves

B. Very tight so it does not slip

C. Very loose so as not to damage the bearings in the alternator

D. Oily so it slides nicely over the pulley grooves

Diodes

A. Convert DC into AC

B. Convert AC into DC

C. Do not get hot

D. Do not exist in the alternator

The ___________ monitors battery voltage

A. Rotor

B. Stator

C. Regulator

D. Brushes

Voltage regulators can be controlled by;

A. The PCM

B. A transistor

C. A relay

D. All of the above

A screeching sound is heard right after startup;

A. The alternator belt is too tight

B. The alternator belt has oil on it

C. The alternator belt is too loose

D. The alternator bearings are bad

The charge lamp

A. Will be on when the vehicle is at KOEO

B. Will be on when the vehicle is at KOER

C. Will be on when the vehicle is overcharging

D. Will be on when the vehicle is off

The charge lamp does not operate, what is the most likely cause?

A. Grounded bulb circuit in regulator

B. Loose belt

C. Burned out bulb

D. Over charged battery

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