Generator (GEN) - 4.2L 8-cylinder engine (Audi S4), removing and installing: Notes

WARNING: This page does not describe the selected car, but rather 16 other vehicles, including the 2009 Audi S4, 2009 Audi A4, 2008 Audi S4, 2008 Audi RS 4, and 2008 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

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 Old Oil Collecting And Extracting Device V.A.G 1782

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Oil drain appliance VAG 1782 or UL approved equivalent

Fig 3: Identifying Hose Clip Pliers Vag 1921

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Hose clip pliers VAG 1921

Fig 4: Identifying Torque Wrench V.A.G. 1331

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

Fig 5: Identifying Torque Wrench V.A.G. 1332

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VAG 1332 Torque wrench (or 40 - 200 Nm equivalent)

Removing

Disconnect battery → Battery in engine compartment, disconnecting and reconnecting .
Use oil drain appliance VAG 1782 (or UL approved equivalent) to draw power steering hydraulic fluid from power steering from reservoir.

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.
Lift vehicle
Remove right front wheel.

Fig 6: Identifying Quick-Release Fasteners And Noise Insulation

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

Fig 7: Removing Right Air Guide In Front Of Auxiliary Cooler

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Remove air guide - arrow - from right auxiliary radiator.

Fig 8: Removing Left Air Guide In Front Of Auxiliary Cooler

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Remove air guide - arrow - from left auxiliary radiator.

Fig 9: Removing Drain Plug On Coolant Thermostat Housing

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Place drip tray VAG 1306 or drip tray for workshop crane VAS 6208 beneath engine.
Remove drain plug - arrow - at thermostat housing and drain engine coolant.

Fig 10: Disconnecting Lower Coolant Hose From Radiator

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Release and pull off bottom coolant hose from radiator - arrow - and drain remaining engine coolant.

Fig 11: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper

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Place oil drain appliance VAG 1782 underneath.
Remove hydraulic hoses - arrows - at rear of lock carrier to power steering cooling line.

Fig 12: Removing Cover In Engine Compartment (Right Side)

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Remove right engine compartment cover - 1 -.

Fig 13: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

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Remove screws - arrows -.
Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 N80 - 1 - at air guide.
Remove air guide - 2 -.

Fig 14: Disconnecting Top Coolant Hose From Radiator

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Remove top coolant hose - arrow - from radiator.

Fig 15: Removing Cover In Engine Compartment (Left Side)

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Remove left engine compartment cover - 1 -.

Fig 16: Removing Electrical Harness Connectors And From Bracket

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Remove electrical connections - 1 - and - 2 - from retainer and disconnect them.
Set aside harness toward lock carrier.

Fig 17: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle

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Disconnect electrical connections for left and right headlamps - arrow -.

Fig 18: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier

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Disconnect electrical connections for both left and right airbag sensors - arrow - on lock carrier.
Set aside harness toward lock carrier.
Remove hood release cable from lock carrier → 55 HOOD, LIDS

Fig 19: Disconnecting Electrical Harness Connector For Right Fan

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Disconnect electrical connection - arrow - for right radiator fan.

Fig 20: Removing Left/Right Air Guides At Radiator

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Remove screws - arrows - and remove right and left radiator air guides.

Fig 21: Removing Power Steering Hydraulic Oil Cooling Pipe

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Unclip temperature sensor - 1 - from retainer and set aside.
Remove power steering cooling line - arrows -.

Fig 22: Removing Coolant Fan Control (FC) Control Module J293 From Radiator

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Remove screw - arrow - and remove cooling fan control module.

CAUTION:

In order not to damage the condensor and refrigerant lines/hoses, ensure refrigerant lines are not excessively bent or tensioned in the following procedures.
Do not open refrigerant circuit!

Fig 23: Disconnecting Electrical Harness Connector At High Pressure Sensor G65

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Disconnect electrical connection - 1 - at High Pressure Sensor G65.
Remove screws - arrows -.
Remove condensor with refrigerant lines attached and lower downward.

Fig 24: Removing Bolts At Left/Right Side Of Bumper

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Remove screws at lock carrier left and right - arrows -.
Remove front hood sealing gasket from lock carrier and fenders.

Fig 25: Removing Bolts At Impact Absorbers At Left/Right

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Remove bolts at impact absorbers - arrows - (left and right).

NOTE:

Use an assistant to remove lock carrier in the following step.
Remove lock carrier and tilt aside (secure against falling).

Fig 26: Removing Hose Clamps And Disconnecting Coolant Hose

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Release hose clamp - 2 - and remove coolant hose from right coolant pipe.
Release hose clamp - 1 - and remove coolant hose from coolant pipe.

NOTE:

Engine shown removed in illustration for clarity.

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

Fig 27: Locating Tensioning Bolt And Ribbed Belt

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Relieve ribbed belt tension by loosening tensioner bolt - arrow -.
Remove ribbed belt from generator pulley.

Fig 28: Removing Tensioning Roller

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Remove bolts - arrows - and remove tensioner.

Fig 29: Removing Generator Bolts

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Remove bolts - arrows -.
Remove generator from bracket and pull forwards.

NOTE:

If generator is difficult to remove from mounting, reinstall mounting bolts loosely and carefully strike bolt heads with hammer in order to loosen mounting threaded bushings.

Fig 30: Disconnecting Coolant Hose On Generator, Electrical Connector & Removing Electrical Wire On Generator

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Release hose clamp - 3 - and remove coolant hose from generator.
Disconnect electrical connection - 1 -.
Remove nut - 2 - and terminal eyelet from generator.
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.

To aid in installation, drive generator mounting bushings back into mounting flanges approx. 4mm.

CAUTION: Tight generator mounting bushings must be made to move freely in order to ensure sufficient clamping force at the specified bolt torque.

Fig 31: Placing Ribbed Belt Over Belt Pulleys

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Note running direction of ribbed belt as previously marked and route as illustrated.

Generator (GEN)
Ribbed belt
Idler
Vibration damper
Tensioning roller

Tension ribbed belt by rotating tensioner counterclockwise with torque wrench until 70 Nm is achieved.

Fig 32: Positioning Torque Wrench On Belt Tensioner Hex Bolt

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Hold and simultaneously tighten tensioner bolt - arrow - to 22 Nm.
Reinstall lock carrier and related assemblies → 50 BODY, FRONT .
Reinstall front bumper → 63 BUMPER .
Top up coolant → 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BHF -
- 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
.

Refill power steering fluid reservoir → 48 - STEERING

CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result.

Reconnect battery. Required steps Reconnecting .
Start engine and check belt running.
Check and adjust headlamps if necessary → 00 - TECHNICAL DATA