Audi Workshop Service and Repair Manuals

Removing and installing alternator - vehicles with TDI engine Special tools and workshop equipment required

t  Engine bung set -VAS 6122-

Removing –  Disconnect earth cable from battery with ignition switched off → Chapter. –  Detach engine cover panel -arrows-.

–  Release hose clips -1- and -2- and detach air hose. –  Seal off open pipes and connections with clean plugs from engine bung set -VAS 6122-.

–  Release hose clip -2-. –  Remove bolts -arrows-. –  Unplug electrical connector -1- at charge pressure sender -G31-/intake air temperature sender -G42- and detach air pipe (right-side). –  Remove poly V-belt → Rep. gr.13.

–  On vehicles with air conditioner, unplug electrical connector -2- at air conditioner compressor regulating valve -N280-.   Caution Risk of damage to air conditioner compressor and refrigerant lines/hoses. Take care to avoid straining, kinking or bending refrigerant lines/hoses. –  Unscrew bolts -arrows- and detach air conditioner compressor -1- (with pipe/hose assembly still connected).

–  Remove bolt -2-.

–  Swivel alternator forwards and unplug electrical connector -3-. –  Pry off protective cap -2- and unscrew nut -1- for terminal 30/B+. –  Unscrew nut -4- and pull off clamp.

–  Unscrew bolt -1- and take out alternator -3- downwards and to the right; on vehicles with air conditioner, it is necessary to move air conditioner compressor to the left (as seen in direction of travel).   Note t  If the alternator sticks in the bracket, screw the bolts back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following: –  To facilitate positioning of alternator, slightly drive back bushes for bolts.   Note t  Stiff alternator mount bushes must be freed; otherwise the clamping force of the bush will not be adequate even when the bolts are tightened to the correct torque. t  Hose connections and air pipes/hoses must be free from oil and grease before fitting. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Install air hoses with screw-type clips and air pipe → Rep. gr.21. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt → Rep. gr.13. –  Connect battery. Steps required → Anchor. –  Start engine and check that belt runs properly.