Alternator: Service and Repair
Generator (GEN) - 4.2L 8-cylinder Engine, Removing And Installing
Special tools, testers and auxiliary items required
- Drip tray VAG 1306 or drip tray for workshop crane VAS 6208
- Oil drain appliance VAG 1782 or UL approved equivalent
- Hose clip pliers VAG 1921
- VAG 133-Torque wrench (or 5-50 Nm equivalent)
- VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)
Removing
- Disconnect battery.
- Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.
CAUTION: The cooling system is pressurized when the engine is warm. Wear gloves and other protection and carefully release system pressure if necessary, before performing repairs.
- Open filler cap for coolant expansion tank.
- Lift vehicle
- Remove right front wheel.
- Release fasteners - 1 - and - 2 - and remove front noise insulation.
- Remove air guide - arrow - from right auxiliary radiator.
- Remove air guide - arrow - from left auxiliary radiator.
- Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 beneath engine.
- Remove drain plug - arrow - at thermostat housing and drain engine coolant.
- Release and pull off bottom coolant hose from radiator - arrow - and drain remaining engine coolant.
- Place oil drain appliance VAG 1782 underneath.
- Remove hydraulic hoses - arrows - at rear of lock carrier to power steering cooling line.
- Remove right engine compartment cover -1-.
- Remove bolts - arrows -.
- Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80 - 1 - at air guide.
- Remove air guide - 2 -.
- Remove top coolant hose - arrow - from radiator.
- Remove left engine compartment cover -1-.
- Pull out electrical connections - 1 - and - 2 - from retainer and disconnect them.
- Set aside harness toward lock carrier.
- Disconnect electrical connections - arrow - to headlamps (both sides).
- Disconnect electrical connections - arrow - to airbag sensors on lock carrier both sides).
- Set aside harness toward lock carrier.
- Remove hood release cable from lock carrier
- Disconnect electrical connection - arrow - for right radiator fan.
- Remove screws - arrows - and remove right and left radiator air guides.
- Unclip temperature sensor - 1 - from retainer and set aside.
- Remove power steering cooling line - arrows -.
- Remove screw - arrow - and remove cooling fan control module.
CAUTION:
- In order not to damage the condensor and refrigerant lines/hoses, ensure refrigerant lines are not excessively bent or tensioned in the following procedures.
- Do not open refrigerant circuit.
- Disconnect electrical connection - 1 - at High Pressure Sensor G65.
- Remove screws - arrows -.
- Remove condenser with refrigerant lines attached and lower downward.
- Remove screws at lock carrier left and right - arrows -.
- Remove front hood sealing gasket from lock carrier and fenders.
- Remove bolts at impact absorbers - arrows - (left and right).
NOTE: Use an assistant to remove lock carrier in the following step.
- Remove lock carrier and tilt aside (secure against falling).
- Release hose clamp - 2 - and remove coolant hose from right coolant pipe.
- Release hose clamp - 1 - and remove coolant hose from coolant pipe.
NOTE: Engine shown removed in illustration for clarity.
CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.
- Relieve ribbed belt tension by loosening tensioner bolt - arrow -
- Remove ribbed belt from generator pulley.
- Remove bolts - arrows - and remove tensioner.
- Remove mounting bolts - arrows -.
- Remove generator from bracket and pull forwards.
NOTE: If generator is difficult to remove from mounting, reinstall mounting bolts loosely and carefully strike bolt heads with hammer in order to loosen mounting threaded bushings.
- Release hose clamp - 3 - and remove coolant hose from generator.
- Disconnect electrical connection -1-.
- Remove nut - 2 - and terminal eyelet from generator.
- Remove generator.
Installing
Install in reverse order of removal, noting the following:
CAUTION:
- Before installing the ribbed belt, ensure that all subassemblies (generator, ale compressor etc.) are securely mounted and turn freely.
- When installing belt, ensure correct seating in the belt pulleys.
- Reinstall all hose clamps, harness retainers and replace all removed cable ties as originally installed in production.
- Note running direction of ribbed belt as previously marked and route as illustrated.
1. Generator (GEN)
2. Ribbed belt
3. Idler
4. Vibration damper
5. Tensioning roller
- Tension ribbed belt by rotating tensioner counterclockwise as illustrated with torque wrench until 70 Nm is achieved.
- Hold and simultaneously tighten tensioner bolt - arrow - to 22 Nm.
- Reinstall lock carrier and related assemblies.
- Reinstall front bumper.
- Top up coolant.
- Refill power steering fluid reservoir.
CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result.
- Reconnect battery. Required steps.
- Start engine and check belt running.
- Check and adjust headlamps if necessary
Tightening torques
Component - fastener Nm
Coolant pipes to generator - bolt 9
Terminal 30/B+ to generator - nut 16
Generator (GEN) to engine bracket - bolt 22
Tensioning roller to engine - bolt 22