Generator (GEN) - 4-cylinder 2.0L Turbo FSI engine, removing and installing: Notes

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Special tools, testers and auxiliary items required

Fig 1: Locking Tool T40098

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Locking pin T40098 or equivalent

Fig 2: Identifying Torque Wrench V.A.G. 1331

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

Removing

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

Fig 3: Removing Engine Cover

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Remove engine cover - arrows -.

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

Fig 4: Pivoting Belt Tensioner For Ribbed Belt To Relieve Tension On Ribbed Belt

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Relieve ribbed belt tension by turning tensioner in direction of - arrow - and lock in place using locking pin T40098.
Remove ribbed belt.

Fig 5: Separating Electrical Connector From Charge Air Pressure Sensor G31 & Removing Left Charge Air Hose

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Remove air hose - 2 - at intake manifold.

NOTE:

Disregard - 1 -.

Fig 6: Identifying Upper And Lower Bolts

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

Fig 7: Generator Electrical Connector And Terminal B+

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Disconnect electrical connection - 2 -.
Remove D+ 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 8: Ribbed Belt, Seated Correctly

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Note running direction of ribbed belt as previously marked and route as illustrated.
Top up coolant → 2.0 Liter 4-Cyl. 4V Turbo Fuel Injection Ignition, Engine Code(s): BPG -
- 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.