With 4.2L FSI

Generator

Special tools, testers and auxiliary items required

• Hose clamps up to 25 mm (3094)

• Hose clamp pliers (VAS 6340)

• Hose clip pliers (VAS 6362)

Removing





- With ignition switched off, disconnect battery ground (ND) wire. Refer to => [ Battery, Disconnecting and Connecting ] Battery, Disconnecting and Connecting.


Hot vapor/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully.

- Open cap of coolant expansion tank.

- Unfasten quick-release fasteners - 1 - and detach front noise insulation.

• Ignore items - 2 to 4 -.

- Remove bolts - arrows - and remove wires with connected hoses - 1 through 4 - from lock carrier.





• Before removing, mark direction of ribbed belt with chalk or felt-tipped pen. Reversing the direction of rotation of a run-in ribbed belt can destroy the belt.





- Pivot tensioner in - direction of arrow - to release tension on ribbed belt.

- Remove ribbed belt and release tensioner.

- Remove screws - arrows -.





- Remove tensioner for ribbed belt from upper part of oil pan.

- Free up secondary air injection (AIR) air guide hose - 1 - on ATF cooler.





- Remove bolts - arrows - and remove ATF cooler.

- Tie ATF cooler with connected coolant hoses and ATF lines on up on engine carrier.

- Clamp off coolant hoses - arrows - with (3094).





• Place a rag under separating point to catch escaping coolant.

- Disconnect coolant hoses - arrows - from coolant pipes.

- Disconnect electrical harness connector - 3 - at generator.

- Remove terminal 30/B+ - item 1 -.

• Disregard item - 3 -.

- Remove the bolts - arrows - and remove generator.





• If generator is stuck in its bracket, screw in mounting bolts again except 2 rotations.

• Carefully strike on bolt heads using flat side of hammer - doing this loosens sleeves of generator mount.

Installing

Install in reverse order of removal, observing the following:

• Secure all hose connections using standard hose clamps.

- slightly drive back sleeves for retaining bolts in order for easier installation of generator.

• Tight sleeves for generator mount must be made smooth-running, otherwise clamping force of sleeve is too little despite correct torque.

- Place ribbed belt - 2 - over belt pulleys in the specified sequence.





1 Generator
3 Idler pulley
4 Vibration damper
5 Tension roller

• When installing poly V-belt, make sure it is properly seated on pulleys.

- Connect battery. Required actions, refer to => [ To connect, connect terminal clamp of ground (GND) wire by hand to battery negative terminal and tighten nut. ] Battery, Disconnecting and Connecting.

- Check coolant level.

- Start engine and check belt routing.

Tightening Specifications