Vehicles with 4-cylinder engine

Special tools and equipment 

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• VAG 1306 drip tray for VAG 1202A

Fig 2: Identifying Hose Clip Pliers Vag 1921

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• VAG 1921 hose clip pliers

Removing 

• Open cap of coolant expansion tank.
• Remove engine cover.

Fig 3: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• For vehicles with auxiliary heater, remove bolts -arrows- for exhaust pipe of stationary heater/auxiliary heater on noise insulation.

Fig 4: Identifying Quick-Release Fasteners And Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove bolts or quick release screws -1- and -2- and remove front noise insulation.
• Place VAG1306 Drip Tray beneath engine.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove retaining clip -1- and remove Engine Coolant Temperature (ECT) Sensor -G2- -2-.
• Drain coolant only from radiator.

Fig 6: Identifying Top Coolant Hose At Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect top coolant hose at coolant pipe -arrow-.

Fig 7: Identifying Coolant Fan Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Unbolt Coolant FC (Fan Control) Control Module -arrow-, disengage control module and set it aside.

Fig 8: Identifying Ribbed Belt Tensioner

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Move ribbed belt tensioner in direction of arrow to release tension on ribbed belt..
• Remove ribbed belt from generator belt pulley.
• Release tensioner.

Fig 9: Identifying Electrical Harness Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Disconnect electrical harness connector -1-.

Fig 10: Identifying Upper And Lower Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Remove upper and lower bolts -arrows-.
• Remove generator.
• Unscrew terminal D+.

Installing 

Installation is reverse order of removal, paying attention to the following:

Fig 11: Ribbed Belt, Seated Correctly

Courtesy of VOLKSWAGEN UNITED STATES, INC.

• Make sure the ribbed belt is seated and installed correctly.
• Fill up with coolant:

Refer to

• 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

• Connect battery. Required steps. Refer to Battery, disconnecting and connecting .
• Start engine and check running of belt.

Tightening torques