Audi Workshop Service and Repair Manuals

Removing and installing alternator - vehicles with 2.0 ltr. TDI engine Special tools and workshop equipment required

t  Locking tool -T40098-

Removing –  Detach engine cover panel -arrows-.

–  Unfasten retaining clips -arrows- and remove toothed belt cover (top).

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 turn tensioner in direction of -arrow-. –  Remove poly V-belt from alternator pulley. –  Secure tensioner with locking tool -T40098-.

–  Release hose clip -2- and detach air hose -3- from throttle valve module -J338-. –  Remove bolt -1-.

–  Unscrew nut -3- and unplug electrical connector -1-. –  Detach continued coolant circulation pump -V51--item 2- with retainer and move clear to one side (with coolant hoses attached).

–  Unscrew centre hex stud -2- and pull coolant pipe -1- (with hoses connected) in direction of -arrow-.

–  Unscrew terminal 30/B+ -item 1-. –  Unplug electrical connector -2-.

–  Unscrew bolts -arrows-.   Note t  If you cannot remove the bolts, press radiator cowl forwards slightly. t  If alternator sticks in retainer, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mount. –  Pull coolant pipe to one side and detach alternator -1-. Installing l  Tightening torque → Chapter 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.

–  Fit poly V-belt onto pulleys in the following sequence: 1 -  Vibration damper 2 -  Air conditioner compressor 3 -  Power steering pump 4 -  Idler roller 5 -  Tensioner 6 -  Alternator   Note When installing poly V-belt, make sure it is properly seated on pulleys. –  Connect battery. Steps required → Anchor. –  Start engine and check that belt runs properly.