Vehicles with 4.2l FSI engines

Fig 1: Hose Clamps Up To 25mm 3094, Hose Clamp Pliers V.A.G 1921, And Pliers For Spring-Type Clamps VAS 5024 A

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Special tools, testers and auxiliary items required

Fig 2: Identifying Noise Insulation And Mountings

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Removing

With ignition switched off, disconnect battery Ground (GND) wire → Battery, disconnecting and connecting .
Remove quick-release screws - 1 - and - 2 -.
Remove pin of expanding clip - arrow - and remove noise insulations.

Fig 3: Identifying Clip, Coolant Fan Control (FC) Control Module J293, And Electrical Harness Connector

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Remove electrical harness connector - 2 - from bracket and disconnect it.
Release clip - arrow - and lay Coolant Fan Control (FC) Control Module J293 - 1 - aside.

Fig 4: Releasing Ribbed Belt Tension

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NOTE:

Mark direction of rotation of ribbed belt using chalk or felt-tip marker before removing. 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.

Fig 5: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan

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Fig 6: Identifying Coolant Hoses And Coolant Pipes

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NOTE:

Fig 7: Identifying Bolts For Generator

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NOTE:

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

Installation is performed in reverse order of removal, noting the following:

NOTE:

Secure all hose connections using hose clamps appropriate for the model type Parts Catalog
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 8: Placing Ribbed Belt Over Belt Pulley

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1 - Generator

3 - Relay pulley

4 - Harmonic balancer

5 - Tensioner roller

NOTE:

When installing ribbed belt, be sure that it is seated correctly on belt pulleys.
Install ribbed belt → 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BVJ - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK .
Connect battery. Required actions Battery, disconnecting and connecting .
Fill with coolant → 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BVJ - 19 - ENGINE - COOLING SYSTEM .
Start engine and check path of belt.

Tightening torques

Component	Nm
Bracket for coolant lines to generator	9
Generator to engine	23
Terminal 30/B+ to generator	16
Tensioner for ribbed belt to upper part of oil pan	22