Charging System: Service and Repair

Generator Clutch









Removal

NOTE: This procedure only applies to the 2.0L GTDI.

1. Remove the generator. For additional information, refer to Generator- 2.0L GTDI .

2. Using a small screwdriver or similar tool, insert the tool through the soft rubber area on the center of the pulley cap and pry off the cap. Discard the cap.

3. NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

NOTE: The shaft and rotor will turn during removal.
Insert a 17 mm hex tool into the clutch pulley. Install an impact gun onto the hex tool and use the impact gun to remove the clutch pulley. A couple of short bursts with the impact gun will remove the clutch pulley.


Installation

1. Hand start the clutch pulley onto the generator shaft.

2. Insert a 17 mm hex tool into the clutch pulley and install a 17 mm, 55 lb-ft torque stick on the hex tool.

3. NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

NOTE: The shaft and rotor will turn during installation.

While holding the outer diameter of the clutch pulley, torque the clutch pulley using the impact gun and the 17 mm, 55 lb-ft torque stick for 3-4 seconds. This makes sure the proper torque has been applied.
- Tighten to 75 Nm (55 lb-ft).


4. Install a new cap onto the pulley with the rubber button facing inwards.

5. Install the generator. For additional information, refer to Generator- 2.0L GTDI .