Removing and installing alternator - vehicles with 1.9 ltr. TDI engine — AUDI

🧭 Before you start

Fits: Audi A3 (8P, 2003–2012)

• Timing position: the crankshaft or camshaft is set and locked during this job

Don't miss

• Leave coolant hose (1) and fuel lines (2) and (3) connected.
• If alternator sticks in bracket, screw bolt back in again down to the last 2 turns.Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings.
• 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.

📋 Procedure

1. With ignition switched off, disconnect earth cable at battery .
2. Remove noise insulation (centre) (fasteners 1 ... 3).
3. Unplug electrical connector (arrow) for magnetic clutch at air conditioner compressor.
4. Lift retaining clip (2) slightly and detach air intake hose (bottom left) from front air pipe.
5. Remove bolt (1).

6. Unclip coolant hose from air pipe (arrow).
7. Raise engine cover panel at the sides (arrows 1) and pull out from the front (arrow 2).
8. Move lines (1 … 3) clear at air pipe.
9. Lift retaining clips (arrows) slightly and remove air pipe. [Note: Leave coolant hose (1) and fuel lines (2) and (3) connected.]
10. Remove bolts (1) and (4).
11. Detach vacuum line (2).
12. Unplug electrical connector (3) at charge pressure sender G31.
13. Unclip coolant hose (5) at air pipe.
14. Pull air pipe approx. 10 cm upwards and towards left side of vehicle, and lay aside.
15. Release retainers and pull fuel filter (with hoses still connected) up out of bracket (arrow) and place to one side.
16. ⚠ 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. — Swivel tensioner in direction of (arrow) to slacken poly V-belt.
17. Lock the poly V-belt tensioner using the locking pin T10060 A.
18. Take off poly V-belt.
19. Unplug electrical connector (2).
20. Unscrew electrical wire (1) at alternator.
21. Unscrew wiring clamp at alternator.
22. Remove bolts (arrows) and lift out alternator. [Note: If alternator sticks in bracket, screw bolt back in again down to the last 2 turns.Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings.]
23. 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.]
24. Fit poly V-belt on pulleys of crankshaft and air conditioner compressor.
25. Finally, fit poly V-belt on alternator pulley and release tensioner.
26. Check correct positioning of poly V-belt.
27. Connect battery. Steps required .
28. Start engine and check that belt runs properly.

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