Removing and installing alternator, all vehicles with 4-cylinder diesel engines — AUDI

🧭 Before you start

Fits: platform codes S1, 2H

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• For reasons of clarity, the following illustration shows the auxiliary heater bracket without the auxiliary heater.

📋 Procedure

1. ⚠ To disconnect and reconnect the battery, the procedure described in the workshop manual should be strictly adhered to . — Switch off ignition and all electrical loads, and pull out ignition key.
2. Disconnect battery .
3. Loosen poly V-belt Power unit13Dismantling and assembling engine.
4. Remove charge pressure pipes (1) in area of alternator.
5. Unscrew bracket of coolant line from engine at top (arrow).

6. Push coolant line (1) to one side and secure to fuel line using a cable tie (2). [Note: To ensure there is sufficient room for removing the alternator on vehicles equipped with an auxiliary heater, release the auxiliary heater far enough to be able to lift it with lines connected Heating, ventilation, air conditioning system82Auxiliary heater; Auxiliary heater; Removing and installing auxiliary heater.]
7. ⚠ Danger of burn injuries.Parts of the exhaust system may be hot.Allow exhaust system to cool before removing. — Remove auxiliary heater silencer together with bracket Heating, ventilation, air conditioning system82Auxiliary heater; Auxiliary heater; Removing and installing silencer with bracket.
8. Remove front left headlightMX1.
9. Unscrew bolt (arrow) from bracket for coolant pipes (1).
10. Unscrew nut (arrow) through opening in headlight, and remove coolant line (1). [Note: For reasons of clarity, the following illustration shows the auxiliary heater bracket without the auxiliary heater.]
11. Remove securing bolts (1).
12. Remove securing bolt (2).
13. Raise bracket and auxiliary heater with lines connected until there is sufficient clearance to be able to remove the alternator.
14. Release and disconnect connector of DF cable (1).
15. Lever off deflector cap (2).
16. Unscrew securing nut and B+ cable below it from connection thread of alternator.
17. Unscrew the two securing bolts (arrows) of alternator.
18. Remove alternator from bracket and turn it so rear side is facing upwards.
19. Use a long screwdriver to release retaining clip (arrow) of wiring connector from alternator.
20. Remove alternator (1) upwards out of engine compartment.
21. ⚠ When fitting used poly V-belts, take note of the direction of rotation as marked during removal!Before installing poly V-belt, ensure that all ancillaries (alternator, air conditioner compressor) are secure.When fitting belt, ensure that poly V-belt seats correctly in pulleys! — Drive threaded sleeve (A) about 4 mm in direction of arrow out of alternator housing.
22. Tighten threaded connections to specified torque given in assembly overview .
23. Specified torques for auxiliary heater Heating, ventilation, air conditioning system82Auxiliary heater; Auxiliary heater; Removing and installing auxiliary heater.
24. Connecting battery .
25. Start engine and check belt running.

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