4.2L 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

Removing

With ignition switched off, disconnect battery Ground (GND) wire → Battery, Disconnecting and Connecting .
Drain coolant →
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
.
Remove right front wheel.
Remove front right wheel housing liner → 66 - EXTERIOR EQUIPMENT .

Fig 2: Hose To Secondary Air Pump At Bottom Of Air Filter Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Detach hose - arrow - to secondary air pump at bottom of air cleaner housing.

Fig 3: Identifying Mass Air Flow (MAF) Sensor Electrical Connector & Air Filter Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Detach air hose - 2 - at air cleaner housing.
Disconnect electrical connector - 1 -.
Remove bolts - arrows - and take out air cleaner housing.

Fig 4: Disconnecting Hose From Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Detach upper coolant hose - arrow - from radiator.

Fig 5: Mounting Plate & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolt - 1 - and detach mounting plate - 2 - beneath it.

Fig 6: Bolt, Electrical Connector & Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Detach wire - 2 - at generator.
Disconnect electrical connector - 1 -.
Free up wiring.
Remove bolt - 3 - and detach securing plate beneath it.

Detach coolant lines at generator.

NOTE:

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.

Fig 7: Pivoting Tensioner In To Release Tension On Ribbed Belt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pivot tensioner in - direction of arrow - to release tension on ribbed belt.
Detach ribbed belt from generator pulley.
Release tensioner.

Fig 8: Alternator Screws

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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.

Remove generator.

Installing

Install in reverse order of removal, observing the following:

NOTE:

Replace seals, gaskets and self-locking nuts.

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 9: Ribbed Belt Routing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position ribbed belt over pulleys in stated sequence.

Upper idler wheel
Crankshaft
Tensioner for ribbed belt
Lower idler pulley
Power steering pump
A/C compressor
Generator

NOTE:

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

Install front right wheelhousing liner → 66 - EXTERIOR EQUIPMENT .
Connect battery. Required actions → Battery, Disconnecting and Connecting .
Fill coolant →
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BVJ
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BFM
.
Start engine and check belt routing.

Tightening Specifications

Component		Nm
Generator to generator bracket		23
Terminal 30/B+ to generator		16
Coolant pipes to	Oil filter bracket	10
	Generator	10