6.0L MPI

Special tools, testers and auxiliary items required

Fig 1: Hose Clamp Pliers V.A.G 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clamp pliers V.A.G 1921

Fig 2: Workshop Crane Drip Tray VAS 6208

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Workshop crane drip tray VAS 6208

Removing

With ignition switched off, disconnect battery Ground (GND) wire → Battery, Disconnecting and Connecting .
Drain coolant → 19 - COOLING SYSTEM .
Move lock carrier to service position → 50 - BODY - FRONT .

Fig 3: Mass Air Flow (MAF) Sensor G70 Electrical Connector, Upper Part Of Air Filter Housing Connections, Intake Manifold Air Duct Hose & Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 - for Mass Air Flow (MAF) Sensor G70.
Detach air hose - 4 - at intake manifold.
Detach bracket for electrical connectors - 2 - and - 3 - at top section of air cleaner housing.
Remove screws - arrows -.

Remove right upper section of air filter housing.

Fig 4: Air Duct & Bolts

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Remove air duct - 1 -.
Remove screws - arrows -.
Remove lower section of right air cleaner housing.

Fig 5: Coolant Hose

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NOTE:

Place a rag under separating point to catch escaping coolant.

Detach coolant hose - arrow - at right on engine.

Fig 6: Pulling Engine Cover At Rear And Middle Upward And Off & Pulling Engine Cover Forward And Off Of Intake Manifold

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Next, carefully remove engine cover at rear and center upward - arrows 1 -.
Then remove engine cover forward from intake manifold - arrows 2 -.

Fig 7: Relieving Tension On Ribbed Belt

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To loosen the poly V-belt, apply pressure to tensioner in direction of the - arrow - using a 30 mm box-end wrench.
Detach ribbed belt from generator pulley.
Release tensioner.

Fig 8: Auxiliary Radiator Coolant Hose & Bolts

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Place Workshop Crane Drip Tray VAS 6208 under engine.
Detach coolant hose (front) at auxiliary radiator - arrow - and allow coolant to drain off.
Remove bolts - 1 - and - 2 -.

Fig 9: Auxiliary Radiator, Coolant Hoses & Bolts

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Detach coolant hoses - arrows -.
Remove bolts - 1 - and - 2 -.
Remove auxiliary radiator.

Fig 10: Generator Electrical Wiring & Electrical Connector

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Detach wire - 1 - at generator.
Disconnect electrical connector - 2 -.

Fig 11: Identifying Generator Bolts

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Remove screws - arrows -.

NOTE:

If alternator sticks in holder, turn bolt back in again down to the last 2 turns.
Tap carefully on bolt heads with flat side of hammer to release threaded bushings of generator mount.

Pivot the alternator slightly down to left.

NOTE:

Two technicians are required for remaining procedures for removing generator.

CAUTION: Coolant will drain out.

Fig 12: Generator Bracket Bolt & Coolant Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Detach coolant hose - 2 - from hose flange at generator.
Mark installation position of hose flange on generator.
Remove bolt - 1 - and remove bracket.
Detach both hose flanges from generator.

Remove generator.

Installing

Install in reverse order of removal, observing the following:

NOTE:

Replace O-ring
Secure all hose connections using standard hose clamps .

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

NOTE:

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

Fig 13: Ribbed Belt Routing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

First fit poly V-belt onto pulley for vibration damper, then onto the remaining pulleys, and lastly onto the tensioning roller.

NOTE:

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

Install right auxiliary radiator → 19 - COOLING SYSTEM .
Connect battery. Required actions → Battery, Disconnecting and Connecting .
Fill coolant → 19 - COOLING SYSTEM .
Start engine and check belt routing.

Install lock carrier with attachments → 50 - BODY - FRONT .
Install front bumper cover → 63 - BUMPERS .

Tightening Specifications

Component	Nm
Hose flange to generator	10
Terminal 30/B+ to generator	16
Generator to engine	23