Audi Workshop Service and Repair Manuals

Removing and installing alternator - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine without auxiliary heater Special tools and workshop equipment required

t  Socket Torx T 60 -T40087-

Removing –  With ignition switched off, disconnect earth cable at battery → Chapter. –  Detach engine cover panel -arrows-.

–  Remove air duct -arrow-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Remove bolt -3- and move clear exhaust gas pressure sensor 1 -G450--item 4- at air pipe. –  Move clear electrical connector -2- for temperature sender after particulate filter -G527- at air pipe. –  Remove air intake hose with air mass meter -G70-. To do so, release hose clip -5- and clamps -arrows-.

–  Disconnect vacuum line -1-. –  Detach air cleaner (bottom section) and unplug electrical connector -2- on back at air filter bypass flap valve -N275-.

–  Remove bolts -2- and -3-. –  Detach air pipe from air hose (release hose clip -1-). –  Remove front right wheel. –  Detach front section of front right wheel housing liner and press to rear → Rep. gr.66.

–  Remove front noise insulation panels (release fasteners -1- and -2-).   Note Disregard -items 3 and 4-.

–  Vehicles with gear oil cooling: Remove bolt -arrow- for ATF lines.

–  Slacken nut -1- on bracket for electrical wiring several turns.   Note Disregard -item 2-.

–  Detach air hose from air pipe (right-side) and move clear to one side (release hose clip -arrow-).

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 of -arrow- using 60 mm Torx socket -T40087-. –  Remove poly V-belt from alternator pulley.

–  Unscrew bolts -arrows- for alternator approx. 6 turns. –  Tap carefully on bolt heads with a hammer to release bushes securing alternator. –  Remove bolts completely.

–  Detach alternator from retainer. –  Unscrew terminal 30/B+ -item 1-. –  Unplug electrical connector -2-. –  Remove alternator downwards. Installing l  Tightening torque → Chapter Installation is carried out in the reverse order; note the following: –  To facilitate positioning of alternator, drive back sliding 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. –  Vehicles with gear oil cooling: secure ATF lines → Rep. gr.37. –  Install air pipe (right-side) → Rep. gr.21.

–  Fit poly V-belt onto pulleys in the following sequence: 1 -  Alternator 2 -  Idler roller 3 -  Idler roller 4 -  Coolant pump 5 -  Idler roller (depending on version) 6 -  Power steering pump 7 -  Air conditioner compressor 8 -  Tensioner for poly V-belt 9 -  Crankshaft   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.