Audi Workshop Service and Repair Manuals

Removing and installing bracket for ancillaries Special tools and workshop equipment required

t  Locking pin -T10060 A- Removing   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Disconnect earth wire at battery with ignition switched off. –  Drain off coolant → Chapter. –  Move lock carrier to service position → Chapter.   Note

Before removing, mark direction of rotation 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. –  Turn tensioner in -direction of arrow- and lock with locking pin -T10060 A- to slacken the poly V-belt. –  Remove poly V-belt.

–  Unplug electrical connector -arrow- at oil level and oil temperature sender -G266-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor with lines attached to left-side of vehicle.

–  Unscrew wire -1- at alternator. –  Unplug electrical connector -2-.

–  Remove bolts -arrows-. –  Remove alternator.

–  Counterhold power steering pump pulley with drift to unbolt pulley -arrows-.

–  Unbolt power steering pump -arrows- and tie up to one side; the hoses/pipes remain connected.

–  Unscrew bolt -arrow- and remove poly V-belt tensioner.

–  Detach coolant hose from hose connection -2-. –  Remove securing bolts -1- for hose connection and remove hose connection with thermostat -4- and O-ring -3-.

–  Remove toothed belt → Chapter. –  Remove the idler roller -arrow-.

–  Unscrew bolts -1 … 6- and remove bracket for ancillaries. Installing Installation is carried out in the reverse order; note the following:   Note t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do NOT use lubricant. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. –  Check that dowel sleeve at top right between bracket for ancillaries and cylinder block is fitted; insert if necessary. –  First tighten bolts in the sequence -1 ... 6- hand-tight, then tighten to specified torque. –  Install toothed belt (adjust valve timing) → Anchor. –  Install vibration damper → Chapter. –  Install thermostat connection together with thermostat → Chapter. –  Install poly V-belt tensioner → Chapter. –  Install power steering pump → Rep. Gr.48. –  Install alternator → Rep. Gr.27. –  Install air conditioner compressor → Rep. Gr.87. –  Install poly V-belt → Chapter. –  Install lock carrier with attachments → Rep. Gr.50.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-. –  Install bumper cover (front) → Rep. Gr.63. –  Connect battery. Procedures required → Rep. Gr.27. –  Fill cooling system → Anchor. Tightening torques

Component	Nm
Bracket for ancillaries to cylinder block	45
Idler roller for toothed belt to bracket for ancillary units	40 + 90° 1)2)
Stop for torque reaction support to lock carrier	28
Hose clips (9 mm wide)	3
Hose clips (13 mm wide)	5.5
l  1) Renew bolts. l  2) 90° = one quarter turn.