Service
ServiceThe upgrade from a 150A air-cooled generator to a 190A liquid cooled generator should be performed if the vehicle has any of the following conditions:
A. Battery related issue.
B. Charging system issue.
C. Persistent load intervention condition.
Before proceeding with any other repairs or the upgrade of the generator, verify the vehicle has any of the above mentioned conditions and is equipped with:
1. HID (high intensity discharge or Bi-Xenon) headlamps.
Tip:
Go to ElsaWeb and enter the VIN. Check under Vehicle Data for PR number 8JD to confirm if vehicle has HID/Bi-Xenon headlamps.
2. Air suspension.
Tip:
Go to ElsaWeb and enter the VIN. Check under vehicle data for PR number 1BK to confirm if vehicle has air suspension.
Is vehicle equipped with either of these options or both?
- Yes, go to step 3.
- No, do not complete this Technical Bulletin. Further diagnosis required.
3. Is vehicle equipped with 150A air-cooled generator?
Tip:
Go to ElsaWeb and enter the VIN. Check under Vehicle Data for PR number 8GR to confirm if vehicle has a 150A generator.
- Yes, go to procedure outlined below to upgrade generator.
- No, do not complete this bulletin. Further diagnosis required.
Procedure to upgrade 150A air-cooled generator to 190A liquid-cooled generator
A. Perform Steps outlined in I before proceeding to steps in II.
B. Do not physically alter any of the parts.
C. Do not substitute any parts other than what is outlined in this Technical Bulletin.
D. If any part does not fit properly or the instructions below are not clear, please contact VW Helpline for further assistance.
I. Removal of 150A air-cooled generator and pre-assembly of new 190A liquid-cooled generator parts
1. Remove 150A air-cooled generator as outlined in Repair Manual (ElsaWeb).
2. Inspect and verify that free-wheeling pulley is functioning properly.
- If so, go to step 3.
- If not, order a new free-wheeling pulley and go to step 4.
- If new 190A liquid-cooled generator is already fitted with a free-wheeling pulley, go to step 5.
3. Remove free-wheeling pulley from 150A air-cooled generator as outlined in Repair Manual (ElsaWeb).
4. Install free-wheeling pulley from step 2 on 190A liquid-cooled generator using special tools # 3400 and # 3410. Tighten pulley to 80 Nm.
5. Install one 0-ring (Part No: N90783401) on each aluminum coolant pipe (Part No: 059121131B). Insert aluminum coolant pipes through mounting plate/hold-down bracket (Part No. 7L0121077). See Figure 1.
6. Lubricate 0-rings with G-12 engine coolant - DO NOT USE SILICONE SPRAY. Install mounting plate/holddown bracket with aluminum coolant pipes into generator. Tighten socket head bolt (Part No. N10190701) to 9 Nm. See Figure 2.
7. Install hose clamps (Part No: N90770201 - black color & Part No: N90655401 - gray color) onto hose (Part No: 7L0121058E).
NOTE:
Black hose clamp should be affixed to end of hose which has the word IN printed on it - this would be the side which is attached to the generator.
The gray hose clamp must be affixed to end which will connect to vehicles coolant system. See Figure 3.
8. Install hose clamps (Part No: N90770201 - small black color and Part No: N90655501 - large black color) onto hose (Part No: 7L0121058F).
Large black hose clamp must be affixed to the large end of hose which will connect to vehicle's cooling system. See Figure 3.
II. Installation of 190A liquid-cooled generator
9. Prior to draining the cooling system, cover the connector housing of the generator harness which was disconnected in Step 1 to ensure that no coolant splashes into connector housing. Drain cooling system as outlined in Repair Manual (ElsaWeb).
10. Remove coolant plugs located on engine cooling system. See Figures 4 and 5.
11. Install inlet hose (Part No: 7L0121058E) onto the small inlet (lower) nipple of the vehicle's cooling system. Retain with clamp Part No: N90655401. Ensure that the hose is fully seated onto the inlet pipe and is not kinked or chafing after installation. See Figure 6.
NOTE:
It may be helpful to use a small mirror and flashlight to verify that hose (part No. 7L0121058E) is fully installed onto the small inlet nipple of the vehicles cooling system and that gray clamp (Part No. N90655401) is properly oriented onto the hose. Final positioning of the hose clamp should be done with VAS special tool 5024A which has the cable attachmen. When the hose clamp is in the correct position, the edge of the hose clamp tabs will contact the engine block. See figure 7
12. Install the outlet hose (Part No: 7L0121058F) onto the outlet (upper) nipple of the vehicle's cooling system. Retain with clamp Part No: N90655501. Ensure that hose is not kinked or chafing after installation. See Figures 6 and 7.
13. Do not mount 190A generator at this point. Insert hoses into generator aluminum coolant pipes. Retain with clamps Part No: N90770201.
NOTE:
Make sure that inlet hose (Part No. 7L0121058E) is connected to port that is labeled IN on generator. Make sure that outlet hose (Part No. 7L0121058E) is connected to port that is labeled OUT on generator. Ensure hose and hose clamps are properly orientated. See Figures 8 and 9
Tip:
Use VAS Special Tool 5024A to install hose clamps at generator. See Figures 10 and 11
14. Mount 190A liquid-cooled generator as outlined in Repair Manual (ElsaWeb).
Tighten bolts to 20 Nm.
15. Install the harness (connector with 2 wires) to the generator. Ensure harness is not strained. See Figure 12.
note:
Ensure that no engine coolant has spilled into the connector housing for the generator. If so, clean connector properly. Failure to do so may lead to contacts becoming corroded and/or charging system malfunction.
16. Install the B+ cable to the generator using the securing nut (Part No: N01100840). Tighten the securing nut to 15 Nm. Ensure the cable is routed properly - See Figure 13.
17. Install protective cap (Part No: N90403002) over B+ securing nut at back of generator.
18. Install ribbed belt as outlined in Repair Manual (ElsaWeb).
19. Prior to reconnecting battery, test battery directly at battery terminals using Midtronics InCharge 940. Perform action as instructed by Midtronics Tester before proceeding to next step.
Tip:
If battery requires charging or replacement, Midtronics test code must be provided in the warranty claim. Failure to provide Midtronics test code may result in a denied claim.
20. Reconnect battery as outlined in Repair Manual (ElsaWeb).
21. Refill coolant system as outlined in Repair Manual (ElsaWeb).
22. Start vehicle and allow vehicle to idle.
23. Using VAS tool, clear all DTCs.
24. Restore electrical power.
25. Check charging system to ensure proper operation and that load intervention condition has been corrected.
26. Inspect cooling system for leaks.
27. Turn engine OFF.
28. Install engine cover (if applicable) as outlined in Repair Manual (ElsaWeb).
29. Install noise dampening pan (if applicable) as outlined in Repair Manual (ElsaWeb).
III. Post Procedure Component Reset / Relearn
30. Access Start Module.
Before starting vehicle, Access Start Module must be reset:
- Turn ignition switch to left most position.
- Let ignition switch return to zero position (at rest when key is in ignition switch).
- Turn ignition switch to the right position to start the engine.
31. Front windows "One touch feature".
With vehicle idling:
- Fully open both front windows.
- Fully close both front windows.
32. Electronic front seat (if equipped) "Soft stop function".
With vehicle idling:
- Hold seat "forward/backward" switch in forward position until front seat moves fully forward and seat stops.
- Release switch.
- Hold seat "forward/backward" switch in forward position to ensure front seat is in fully forward position.
- Release switch.
- Forward soft stop position is learned.
- Hold seat "forward/backward" switch in backward position until front seat moves fully backward and seat stops.
- Release switch.
- Hold seat "forward/backward" switch in backward position to ensure front seat is in fully backward position.
- Release switch.
- Backward soft stop position is learned
33. Repeat steps in step 31 for other front seat.
34. Electronic steering column (if equipped).
With vehicle idling:
- Operate steering column adjustment switch in each direction (up, down, forward and backward) until steering column stops in that direction.
35. Steering angle sensor & Air suspension.
- Steering angle sensor will temporarily lose calibration (light will illuminate) and must relearn its position.
- Air suspension will temporarily lose communication with the steering wheel angle sensor (light will illuminate).
- Drive vehicle forward with wheels in the straight ahead position for approx. 45 ft. (13.7 meters).