Audi Workshop Service and Repair Manuals

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

t  Open-end spanner -3312-

Removing –  With ignition switched off, disconnect earth cable at battery → Chapter. –  Remove air cleaner cover -2- (if fitted). –  Remove air duct -1- going to air cleaner housing.

–  Remove noise insulation -arrows-. –  Remove front bumper → Rep. Gr.63. –  Move lock carrier to service position → Rep. Gr.50.

–  Unscrew viscous fan (counterhold with 32 mm ring spanner).

–  Open clamps -arrows- and remove toothed belt guard (left and right).

–  Remove poly V-belt cover -arrows-.   Note Note spacer sleeves for poly V-belt cover.   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. –  In order to slacken the poly V-belt, swivel the tensioner in direction of -arrow- using an Allen key. –  Lock tensioner by inserting locking pin Ø 4 mm -item 1- in locating holes. –  Remove poly V-belt from alternator pulley.

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

–  Unscrew bolts -1- and -2-.   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.

–  Unplug electrical connector -arrow- at engine mounting.   Caution When removing alternator, the refrigerant lines must be pushed aside very carefully. –  Remove alternator towards bottom. 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.

–  Make sure poly V-belt is properly positioned and correctly routed. 1 -  without air conditioning system 2 -  with air conditioning system

–  Secure viscous fan using open-end spanner -3312-.

Tightening torque for viscous fan	Nm
Torque wrench -V.A.G 1331- and open-end spanner -3312-	37
Torque wrench -V.A.G 1331- without open-end spanner -3312-	70

–  Remove locking pin -1-; to do so, turn tensioner in direction of -arrow- using Allen key. –  Install lock carrier with attachments → Rep. Gr.50. –  Install front bumper → Rep. Gr.63. –  Connect battery. Additional steps required → Anchor. –  Start engine and check that belt runs properly. Tightening torques

Component		Nm
Alternator to engine	M8	22
	M10	45
30/B+ terminal to alternator		16
D+ terminal to alternator		4
Poly V-belt cover to bracket		10