Audi Workshop Service and Repair Manuals

Vehicles with 2.5 ltr. TDI engine Special tools and workshop equipment required

t  Open-end spanner -3312-

t  Pin -T10060 A-

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

–  Remove engine cover -arrows-. –  Move lock carrier to service position → Rep. Gr.50.

–  Remove viscous fan. –  Remove toothed belt cover (front left and right).

–  Remove poly V-belt cover -arrows-.   Note Note spacer sleeves for poly V-belt cover.

–  On vehicles with auxiliary heater, unscrew bolts -arrows- for exhaust pipe of auxiliary/supplementary heater at noise insulation.

–  Unfasten bolts/quick release fasteners -1- and -2- and detach noise insulation (front). –  Detach cap from tensioning roller for air conditioner compressor.

–  Loosen bolt -arrow- of tensioning roller for air-conditioner compressor and take off poly V-belt.

–  Turn hexagon key in direction of -arrow- until the two holes align and insert locking pin -T10060 A-. –  Remove poly V-belt from alternator pulley. –  Unscrew wire for terminal 30/B+ at alternator. –  Unplug connector for terminals DF and D+.

–  Unscrew bolts -1- and -2-. –  Unplug electrical connector for electro-hydraulic engine mounting. –  Remove alternator towards bottom.   Caution When removing alternator, the refrigerant lines must be pushed aside very carefully.

Installing Installation is carried out in the reverse order; note the following: –  Make sure poly V-belt is properly positioned and correctly routed.

–  Remove locking pin -T10060 A-; to do so, turn hexagon key in direction of -arrow-. –  Fit poly V-belt for air conditioner compressor.

–  Apply torque wrench -C- with 8 mm hexagon key as shown in the illustration and tension poly V-belt to 7 Nm by turning in direction of -arrow-. –  At the same time, use torque wrench to tighten bolt -A-. l  Tightening torque: 22 Nm. –  Press on cover for tensioning roller.

–  Use open-end spanner -3312- to secure viscous fan.

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

–  Connect the battery. Additional steps required → Anchor. –  Start engine and check that belt runs properly. Tightening torques

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