Audi Workshop Service and Repair Manuals

Vehicles with 1.8 ltr. turbo and 2.0 ltr. MPI engine Special tools and workshop equipment required

t  Hose clip pliers -V.A.G 1921-

t  Drip tray for workshop hoist -VAS 6208- Removing –  With ignition switched off, disconnect earth cable at battery → Chapter.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  Cover cap for coolant expansion tank with a cloth and open carefully to release pressure. –  Open filler cap for coolant expansion tank. –  Remove engine 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).

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Pull out retaining clip -1- and detach radiator outlet coolant temperature sender -G83--item 2-. –  Drain off coolant at radiator only.

–  Detach coolant hose (top) at coolant pipe -arrow-.

–  Unscrew radiator fan control unit -arrow-, detach control unit and lay it aside.

Caution Risk of breakage if the poly V-belt runs in the opposite direction when refitted. Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen in preparation for re-installation. –  To slacken poly V-belt, pivot tensioner in direction indicated -arrow-. –  Remove poly V-belt from alternator pulley. –  Release pressure from tensioner.

Vehicles with 2.0 ltr. engine: –  Unplug electrical connectors -2- and -3-.   Note Disregard -item 1-.

All models: –  Unscrew bolts (top and bottom) -arrows- and pivot the alternator forwards.

–  Unplug electrical connector -2-. –  Unscrew D+ terminal -item 1-. –  Take out alternator.

Installing Installation is carried out in the reverse order; note the following: –  Fit poly V-belt on pulleys as illustrated. –  Fill with coolant → Rep. Gr.19. –  Connect battery. Steps required → Anchor. –  Start engine and check that belt runs properly. Tightening torques

Component	Nm
Alternator to engine	23
Terminal 30/B+ to alternator	16