Audi Workshop Service and Repair Manuals

Vehicles with 4-cyl. TDI engine Special tools and workshop equipment required

t  2-hole pin wrench -3212-

Removing –  With ignition switched off, disconnect earth cable at battery → Chapter. –  Unscrew bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Loosen fasteners -arrows A- and -arrows B- and remove front noise insulation. –  Remove front bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.   Note Before removing, mark running direction of poly V-belt with chalk or felt-tipped pen. If the poly V-belt runs in the opposite direction when it is refitted, this can cause breakage.

Vehicles with distributor-type injection pump (TDI engine): –  To slacken poly V-belt, pivot tensioner in direction indicated -arrow-.

Vehicles with unit injector TDI engine: –  To slacken poly V-belt, pivot tensioner in direction indicated -arrow-. All models: –  Remove poly V-belt from alternator pulley. –  Release pressure from tensioner.

–  Counterhold on pulley for viscous fan with 2-hole pin wrench -3212- and unscrew from bracket using 8 mm Allen key.

–  Unscrew 30/B+ terminal wiring -item 1- from alternator. –  Unscrew D+ terminal -item 2-. –  Unplug electrical connector for terminal DF -item 3-. –  Disengage wiring harness from cable tie.

–  Unscrew bolts -1- and -2-. –  Carefully move coolant hose to one side and lift out alternator.   Note t  If alternator sticks in bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release threaded bushes of alternator mount. Installing Installation is carried out in the reverse order; note the following: –  To facilitate positioning of alternator, drive back bushes for securing bolts slightly.   Note 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.

–  Start by fitting securing bolt -1- for alternator. –  Make sure poly V-belt is properly positioned and correctly routed.

Vehicles with distributor-type injection pump (TDI engine): 1 -  without air conditioning system 2 -  with air conditioning system

Vehicles with unit injector TDI engine: All models: –  Connect battery. Additional steps required → Anchor. –  Start engine and check that belt runs properly. Tightening torques

Component		Nm
Alternator to engine	M8	25
	M10	45
30/B+ terminal to alternator		16
D+ terminal to alternator		4