Removal and installation the generator (VW Passat B3)

Up to 9/93: carburetor or injection engine, 8-valve

• 1 - V-belt
• 2 - cylindrical head bolt, 35 Nm

With internal hexagon socket, M8x90 mm.

• 3 — bushing
• 4 — bracket
• 5 - washer
• 6 - Hexagon head bolt
• 7 - Hexagon head bolt
• 8 - hairpins
• 9 - alternating current generator
• 10 — fan wheel

The direction of rotation is indicated by an arrow.

• 11 — pulley

The diameter is 70 mm.

• 12 - nut, 50 Nm
• 13 - washer
• 14 — bolt, 35 Nm, M8x35 mm
• 15 - tension nut
• 16 - tension bar
• 17 - lifting eye
• 18 — bolt, 20 Nm, M8x25 mm
• 19 - washer
• 21 - spacer washer
• 22 - washer

From 10/93: Vehicle with diesel or petrol engine with injection system and power steering

• 1 — bracket
• 2 - nut, 30 Nm
• 3 - alternating current generator
• 4 - voltage regulator
• 5 — bolts M4x25
• 6 — lid
• 7 - M3 screws
• 8 - poly V-belt
• 9 — bushing with internal thread M8
• 10 - tension spring
• 11 — bolt M8x39, 25 Nm
• 12 — bolt M8x85, 25 Nm

From 10/93: Vehicle with 4-cylinder engine with fuel injection, power steering and air conditioning

• 1 — bracket
• 2 - tension element for tension roller
• 3 - nut, 30 Nm
• 4 - alternating current generator
• 5 - voltage regulator
• 6 — bolts M4x25
• 7 — lid
• 8 - screws M3x18
• 9 - poly V-belt
• 9 - bushing with internal thread M8
• 10 — bolt M8x85, 25 Nm
• 11 - tension roller

Removal

Disconnect the battery ground (-) cable.

If a used belt is to be reinstalled, mark the direction of rotation with chalk to ensure correct positioning. Loosen and remove the V-belt, see chapter "Engine".

Models without tension roller: loosen the tension bolt.

Generator BOSCH

VALEO Generator

Disconnect the black (B+) and blue (D+) wires. The arrow points to the B+ wire to the noise suppression capacitor.


Unscrew the wiring harness strain relief and set the electrical wires aside.

Unscrew the generator mounting bolt to the support. To do this, for petrol 4-cylinder engines up to 9/93, remove the protective cap from the toothed belt casing, insert a 6 mm wrench with an external Allen key through the hole and loosen the support bolt.

Loosen the bolt securing the generator to the support bracket and remove the generator.

Installation

Place the generator and screw it to the support bracket.

Insert the protective cap into the upper hole of the timing belt cover.

Models without V-belt tensioner roller: Insert the bolt into the tension bar.

Check the V-belt for wear. When installing a used belt, keep its direction of rotation the same.

Place the V-belt on and tighten it.

Connect the electrical wires to the generator. Screw on the strain relief device for the wiring harness.

Connect the ground wire to the battery.