Audi Workshop Service and Repair Manuals

Vehicles with 6-cyl. bi-turbo engine Special tools and workshop equipment required

t  Locking pin -T10060 A-

Removing –  With ignition switched off, disconnect earth cable at battery → Chapter. –  Remove noise insulation -arrows-. –  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 belt runs in the opposite direction when it is refitted, this can cause breakage. –  In order to slacken the poly V-belt, swivel the tensioner in direction of -arrow- using a 17 mm ring spanner. –  Lock tensioner by inserting locking pin -T10060 A- in locating holes -arrows-. –  Remove poly V-belt from alternator pulley.

–  Remove air intake hose going to charge air cooler (right-side) -arrows-.   Note

To avoid damage to the refrigerant pipes/hoses, take care not to strain, kink or bend pipes and hoses. –  Unscrew nut -1- and remove bracket for refrigerant line. –  Unscrew nut -2- and remove bracket for gear oil lines.   Note Disregard -item 3-.

–  Unscrew bolts -arrows-. –  Loosen clip -1- and remove air pipe (right-side) -2- from turbocharger.

–  Detach wires -1- and -2- at alternator. –  Move wiring harness clear.

–  Unscrew bolts -arrows-.   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. –  Remove alternator. Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  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.

–  Position poly V-belt over pulleys in the following sequence: 1 -  Alternator 2 -  Idler roller 3 -  Coolant pump 4 -  Power steering pump 5 -  Air conditioner compressor 6 -  Tensioner for poly V-belt 7 -  Crankshaft   Note When installing poly V-belt, make sure it is properly seated on pulleys. –  Install lock carrier with attachments → Rep. Gr.50. –  Install front bumpers → Rep. Gr.63. –  Connect battery. Additional steps required → Anchor. –  Start engine and check that belt runs properly. Tightening torques

Component	Nm
Alternator to engine	23
30/B+ terminal to alternator	16
Air intake pipe to sump (top section)	10
Bracket for refrigerant line to sump (top section)	9
Clamp to bracket for refrigerant line	9