TSB : Generator (GEN) - 4.2L 8-cylinder FSI engine (Audi RS4), removing and installing: Notes

Details

Special tools, testers and auxiliary items required Fig 1: Identifying Old Oil Collecting And Extracting Device V.A.G 1782 Courtesy of VOLKSWAGEN UNITED STATES, INC. oil drain appliance VAG 1782 or UL approved equivalent Fig 2: Drip Tray For VAS 6100, VAS 6208 Courtesy of VOLKSWAGEN UNITED STATES, INC. Workshop crane drip tray VAS 6208 or drip tray VAG 1306 Fig 3: Identifying Torque Wrench V.A.G. 1331 Courtesy of VOLKSWAGEN UNITED STATES, INC. VAG 1331 Torque wrench (or 5 - 50 Nm equivalent) Fig 4: Identifying Torque Wrench V.A.G. 1332 Courtesy of VOLKSWAGEN UNITED STATES, INC. VAG 1332 Torque wrench (or 40 - 200 Nm equivalent) Removing Disconnect battery → Battery in luggage compartment, disconnecting and connecting . 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 5: Removing Quick-Release Fasteners, Screws And Noise Insulation Courtesy of VOLKSWAGEN UNITED STATES, INC. Release fasteners - 1 - and - 2 - and remove front noise insulation. Remove right front wheelhouse liner → 66 EXTERIOR EQUIPMENT . Remove front bumper cover → 63 BUMPER Front bumper cover, removing and installing. Fig 6: Removing Right Air Guide In Front Of Auxiliary Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove right air duct - arrow - in front of auxiliary radiator. Place oil drain appliance VAG 1782 (or UL approved equivalent) under engine. Drain engine oil. Fig 7: Removing Bolts On Oil Cooler Lines At Upper Part Of Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws - arrows - at oil cooler lines on upper part of oil pan. Remove oil lines from upper part of oil pan. Fig 8: Removing Left Air Guide In Front Of Auxiliary Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove left air duct - arrow - in front of auxiliary radiator. Fig 9: Removing Bolt On Auxiliary Cooler Upper Bracket, At Left Of Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws - arrow - at upper left auxiliary radiator bracket at lock carrier. Place workshop crane drip tray VAS 6208 or VAG 1306 under engine. Fig 10: Removing Drain Plug On Coolant Thermostat Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove drain plug - arrow - at coolant regulator housing and drain coolant at engine. Fig 11: Removing Drain Plug On Front Coolant Pipe Courtesy of VOLKSWAGEN UNITED STATES, INC. Also remove drain plug - arrow - at front coolant pipe and drain remaining coolant. Fig 12: Removing Coolant Hose Downward From Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Loosen hose clamp - arrow - and remove lower coolant hose from radiator. Place oil extractor VAG 1782 under engine. Fig 13: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect hydraulic lines to rear left radiator coil on lock carrier - arrows -. Fig 14: Identifying Bolts & Air Duct Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws - arrows -. Remove air duct - 1 - and - 2 -. Fig 15: Disconnecting Top Coolant Hose From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. Detach upper coolant hose - arrow - from radiator. Fig 16: Removing Cover In Engine Compartment (Left Side) Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove cover - 1 - at left of engine compartment. Fig 17: Removing Electrical Harness Connectors From Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove electrical connections - 1 - and - 2 - from retainer and disconnect. Set aside harness toward lock carrier. Fig 18: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect electrical connections for left and right headlamps - arrow -. Fig 19: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect electrical connections for left and right airbag sensors - arrow - at lock carrier. Set aside harness toward lock carrier. Remove hood cable at lock carrier → 55 HOOD, LIDS . Fig 20: Disconnecting Electrical Harness Connector For Right Fan Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect electrical connection for right radiator fan - arrow -. Fig 21: Removing Bolts On Left/Right Air Guides At Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws - arrows - at left and right air ducts on radiator. 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 22: Disconnecting Electrical Harness Connector At High Pressure Sensor G65 Courtesy of VOLKSWAGEN UNITED STATES, INC. Disconnect electrical connection - 1 - for High Pressure Sensor G65. Remove screws - arrows -. Remove condenser and swing downward with refrigerant lines connected. Fig 23: Removing Right Coolant Hose Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove right coolant hose - arrow - at radiator. Fig 24: Removing Bolts At Left/Right Side Of Bumper Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws - arrows - at left and right lock carriers. Remove engine compartment seat at lock carrier and fender edges. Fig 25: Removing Bolts At Impact Absorbers At Left/Right Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove screws on left and right shock absorbers - arrows -. NOTE: Use an assistant to remove lock carrier in the following step. Remove lock carrier and tilt aside (secure against falling). CAUTION: Before removing ribbed belt, mark direction of rotation. Belt damage will result if not reinstalled in proper direction. Fig 26: Releasing Ribbed Belt Tension Courtesy of VOLKSWAGEN UNITED STATES, INC. Relieve ribbed belt tension by pivoting tensioner in direction of - arrow -. NOTE: Ensure lever axle is long enough so that it can be completely inserted in tensioner. Remove ribbed belt from generator pulley. Release tensioner. Fig 27: Removing Bolts & Ribbed Belt Tensioner At Upper Part Of Oil Pan Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolts - arrows -. Remove tensioner - 1 - at upper part of oil pan. Fig 28: Removing Bolts And Coolant Hose From Coolant Pipe Bracket And Generator Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove bolt - 2 - on coolant pipe bracket. Loosen hose clamp and remove coolant hose - 1 - to generator. Remove bolts - 3 - and - 4 -. Remove generator from bracket and pull forward. 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 29: Identifying Coolant Hose, Electrical Connector, Bolt & Heat Shield Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove coolant hose - 1 - from generator. Disconnect electrical connection - 5 -. Remove screw - 4 - and remove heat shield. CAUTION: Ensure coolant pipes do not slip out, otherwise O-rings on removed coolant pipes must be replaced. Re-tighten bracket - 3 - after removing heat shield if necessary. Remove nut - 2 - and terminal 30 ( B+ ) 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 30: Placing Ribbed Belt Over Belt Pulleys Courtesy of VOLKSWAGEN UNITED STATES, INC. Note running direction of ribbed belt as previously marked and route as illustrated. Generator Ribbed belt Idler pulley Vibration damper Tensioning roller Install lock carrier with attachments → 50 BODY, FRONT . Install front bumper cover → 63 BUMPER Front bumper cover, removing and installing. Before starting engine for first time, fill hydraulic oil in power steering reservoir. CAUTION: Power steering pump must NOT be allowed to run dry. Damage will result. Fill engine oil and check oil level. Top up coolant → 4.2 Liter V8 5V Engine Mechanical, Engine Code(s): BNS - 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 Connecting Start engine and check belt routing. Check and adjust headlamps → 00 - TECHNICAL DATA .