Generator (GEN) - 4-cylinder 1.8L Turbo engine, removing and installing: Notes

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Special tools, testers and auxiliary items required

Fig 1: Identifying Drip Tray V.A.G 1306

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Drip tray VAG 1306 or drip tray for workshop crane VAS 6208

Fig 2: Identifying Hose Clip Pliers Vag 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Hose clip pliers VAG 1921

Fig 3: Identifying Torque Wrench V.A.G. 1331

Courtesy of VOLKSWAGEN UNITED STATES, INC.

VAG 1331 Torque wrench (or 5 - 50 Nm equivalent)

Removing

Disconnect battery → Battery in engine compartment, disconnecting and reconnecting .

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.
Remove engine cover.
Lift vehicle.

Fig 4: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release fasteners - 1 - and - 2 - and remove front noise insulation.

Fig 5: Locating Retaining Clip And Engine Coolant Temperature (ECT) Sensor

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 below engine.
Pull off retaining clip - 1 - and pull out Engine Coolant Temperature (ECT) Sensor (on Engine) G83 - 2 -.
Drain coolant from radiator only.

Fig 6: Identifying Top Coolant Hose At Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect top coolant hose from coolant pipe - arrow -.

Fig 7: Identifying Coolant Fan Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove radiator fan control module - arrow - and set aside.

CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction.

Fig 8: Identifying Ribbed Belt Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Relieve ribbed belt tension by turning tensioner in direction of - arrow -.
Remove ribbed belt from generator pulley.
Release pressure from the tensioner.

Fig 9: Identifying Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection - 1 -.

NOTE:

Electrical connections - 2 - and - 3 - not applicable to US/CDN models.

Fig 10: Identifying Upper And Lower Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove top and bottom bolts - arrows - and swing generator forward.

Fig 11: Generator Electrical Connector And Terminal B+

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connection - 2 -.
Remove 30 ( B+ ) terminal - 1 -.
Remove generator.

Installing

Install in reverse order of removal, noting the following:

CAUTION:

Before installing the ribbed belt, ensure that all subassemblies (generator, a/c 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.

Fig 12: Ribbed Belt, Seated Correctly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Note running direction of ribbed belt as previously marked and route as illustrated.
Top up coolant → 1.8 Liter 4-Cyl. 5V Turbo Engine Mechanical, Engine Code(s) AMB -
- 19 - ENGINE - COOLING SYSTEM for 1.8 LITER 4-CYL. 5V TURBO ENGINE MECHANICAL, ENGINE CODE(S): AMB
- 19 - ENGINE - COOLING SYSTEM for 2.0 LITER 4-CYL. 4V TURBO ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
- 19 ENGINE - COOLING SYSTEM for 3.0 LITER 6-CYL. 5V ENGINE MECHANICAL, ENGINE CODE(S): AVK, BGN
- 19 - ENGINE - COOLING SYSTEM for 3.2 V6 4V ENGINE MECHANICAL, ENGINE CODE(S): BKH
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 4V ENGINE MECHANICAL, ENGINE CODE(S): BNS
- 19 - ENGINE - COOLING SYSTEM for 4.2 LITER V8 5V ENGINE MECHANICAL, ENGINE CODE(S): BHF
.
Reconnect battery. Required steps Reconnecting .
Start engine and check belt running.