Removing and installing alternator - vehicles with 2.0 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

• Disregard (items 2 and 3).
• If necessary, disengage fuel hoses from retainer.Disregard (items 5 and 6).
• If alternator sticks in bracket, screw bolts 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.
• When installing poly V-belt, make sure it is properly seated on pulleys.

📋 Procedure

1. With ignition switched off, disconnect earth cable at battery .
2. Remove noise insulation (1)50.
3. Remove front right wheel housing liner 66.
4. Remove radiator cowl 19.
5. ⚠ 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 clockwise (arrow).

6. Secure tensioner with locking pin T10060 A.
7. Take off poly V-belt.
8. Unplug electrical connector (2) at air conditioner compressor regulating valve N280.
9. ⚠ Risk of damage to air conditioner compressor and refrigerant lines/hoses.Take care to avoid straining, kinking or bending refrigerant lines/hoses. — Unscrew bolts (arrows) and detach air conditioner compressor (1) (with refrigerant lines still connected).
10. Detach engine cover panel (arrows).
11. Remove bolts (1) and (3).
12. Unplug electrical connector (4).
13. Unfasten clamp (5) at intake manifold flap motor V157 and pull off air pipe (2).
14. Remove bolt (1). [Note: Disregard (items 2 and 3).]
15. Loosen bolt (1).
16. Remove bolt (2) and nut (3).
17. Detach hose retainer (4) at fuel filter and place fuel filter (7) to one side (with fuel hoses connected). [Note: If necessary, disengage fuel hoses from retainer.Disregard (items 5 and 6).]
18. Remove bolt (2).
19. Swivel alternator forwards and unplug electrical connector (3).
20. Pry off protective cap (2) and unscrew nut (1) for terminal 30/B+.
21. Unscrew nut (4) and pull off clamp.
22. Unscrew bolt (1) and take out alternator (3) downwards and to the right; to do so, move air conditioner compressor to the left (as seen in direction of travel). [Note: If alternator sticks in bracket, screw bolts 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, slightly drive back bushes for bolts. [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. Install air pipe 21.
25. Install air conditioner compressor 87.
26. Install radiator cowl 19.
27. Position poly V-belt on pulleys:
28. Use ring spanner to hold tensioner and pull out locking pin T10060 A.
29. Release pressure from tensioner. [Note: When installing poly V-belt, make sure it is properly seated on pulleys.]
30. Connect battery. Steps required .
31. Start engine and check that belt runs properly.
32. Install front right wheel housing liner 66.
33. Install noise insulation 50.

Other AUDI procedures

• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures
• Removing and installing outer tail light cluster – Audi A8 D3
• Removing and installing roof aerial R216, Sportback – Audi A5
• Removing and installing brake caliper piston (1LT)
• Removing and installing side member trim - all vehicles except Audi RS 5
• Removing and installing noise insulation - Audi RS 5 – Audi A5