4.2L FSI

Generator

Special tools, testers and auxiliary items required

• Hose Clip Pliers (VAS 6362)

Observe notes on contact corrosion => [ Contact Corrosion ] Contact Corrosion.

Removing






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

- Drain coolant.

- Remove coolant hose - arrow - to radiator from right coolant pipe.

- Remove bolt - arrow -.













Risk of destroying if the running direction of a used ribbed belt is reversed.

• Before removing ribbed belt, marking running direction with chalk or a felt-tip pen for reinstallation.

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

- Remove ribbed belt and release tensioner.

- Remove screws - arrows - and remove ribbed belt tensioner from upper part of oil pan.






- Remove fan shroud.

- Cut through cable ties and remove air guide hose to secondary air injection combi-valves - upper arrows -.






- Remove right air filter housing.

- Remove the bolts - arrows - and remove generator.






• If alternator sticks in holder, install screw again down as far as the last 2 turns.

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

- Remove screw - 3 - and remove coolant pipe bracket.






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

- Remove coolant pipes - 2 - and - 4 - from generator.

- Disconnect electrical connector - 5 - on generator.

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

Installing

Install in reverse order of removal, observing the following:

• Replace self-locking nuts.

• Replace O-ring

• Secure all hose connections using standard hose clamps. Refer to Electronic Parts Catalog.

- 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 ribbed belt, be sure that it is seated correctly on belt pulleys.

- Connect battery. Refer to => [ Connecting ] Battery, Disconnecting and Connecting.

- Install right air filter housing.

- Install fan shroud.

- Secure ATF lines.

- Fill coolant.

- Check ATF level.

- Start the engine and verify that the belt is running properly.

Tightening Specifications