Removing and Installing the Alternator

Alternator 1 – V-ribbed belt 2 – alternator 3 – voltage regulator 4 – bolts 5 – protective cover 6 – bolts 7 – bolts, 50 N·m 8 – bolts, 50 N·m 9 – bracket 10 – belt tensioner 11 – bolts, 45 N·m

Petrol Engine REMOVAL

PROCEDURE

1. Disconnect the battery ground cable (–) with the ignition switched off.

CAUTION

As a result, data in the electronic control unit memories is erased, such as the radio code. Without the code, the radio can only be activated by its manufacturer, e.g. AUDI radio by AUDI service. Therefore, read the instructions in the subsection Removing and Installing the Battery.

2. Unscrew the mounting bolts and remove the engine cover. To do this, remove the plugs and unscrew the nuts (arrows in the illustration). The illustration shows the 1.6 L AEH engine.

3. Mark the direction of rotation of the V-ribbed belt. To do this, draw an arrow in the direction of rotation with chalk. Looking at the belt from the side, the V-ribbed belt rotates clockwise.

4. Remove the V-ribbed belt; refer to the subsection Removing and Installing the V-Ribbed Belt.

5. Unscrew the 3 mounting bolts of the V-ribbed belt tensioner.

6. Disconnect the electrical wire –1– (terminal 30/B+).

7. Disconnect the cable clip –3–.

8. Disconnect the connector –2– by pressing in the wire clip.

9. Unscrew the mounting bolts and remove the alternator from the bracket. INSTALLATION

10. Before installation, press the threaded bushings for the mounting bolts approximately 1 mm into the alternator (B).

11. Install the alternator on the bracket and tighten to 25 N·m.

12. Tighten the electrical wires to 15 N·m and connect them. Tighten the cable clip to 15 N·m.

13. Tighten the belt tensioner to 25 N·m.

14. Install the V-ribbed belt; refer to the subsection Removing and Installing the V-Ribbed Belt.

15. Install the engine cover and secure it with the bolts.

16. Connect the battery ground cable (–).

CAUTION

Activate the automatic high-position function of the electric window regulator, and set the clock and enter the radio code; refer to the subsection Removing and Installing the Battery.

Diesel Engine REMOVAL

17. Disconnect the battery ground cable (–) with the ignition switched off.

CAUTION

As a result, data in the electronic control unit memories is erased, such as the radio code. Without the code, the radio can only be activated by its manufacturer, e.g. AUDI radio by AUDI service. Therefore, read the instructions in the subsections Removing and Installing the Battery and Entering the Radio Code.

18. Remove the engine cover as follows (refer to the accompanying illustration):

– Remove plug –1–. – Unscrew the nuts (arrows). – Remove clip –2– from pin –3– and remove the cover.

19. Remove the sound insulation element in the center and on the right.

20. Disconnect the electrical wire –1– (terminal 30/B+); refer to the illustration.

21. Disconnect the cable clip –3–.

22. Disconnect the connector –2– by pressing in the wire clip.

23. Mark the direction of rotation of the V-ribbed belt. To do this, draw an arrow in the direction of rotation with chalk. Looking at the belt from the side, the V-ribbed belt rotates clockwise.

24. Remove the V-ribbed belt; refer to the subsection Removing and Installing the V-Ribbed Belt.

25. Unscrew the 3 mounting bolts of the V-ribbed belt tensioner.

26. Air conditioning: Unscrew the mounting bolts (A), remove the compressor and suspend it from the body with the wires still connected.

27. Vehicles with heavy-duty cooling: Remove the additional fan on the right. Protect the radiator from damage with cardboard.

28. All vehicles: Unscrew the mounting bolts and remove the alternator, lifting it upward. INSTALLATION

29. Before installation, press the threaded bushings for the mounting bolts approximately 1 mm into the alternator; see also (B).

30. Install the alternator on the bracket and tighten to 25 N·m.

31. Vehicles with heavy-duty cooling: Install the additional fan on the right and remove the cardboard.

32. Air conditioning: Secure the compressor to the bracket and tighten to 45 N·m.

33. Tighten the belt tensioner to 25 N·m.

34. Install the V-ribbed belt; refer to the subsection Removing and Installing the V-Ribbed Belt.

35. Tighten the electrical wires to 15 N·m and connect them. Tighten the cable clip to 15 N·m.

36. Install the sound insulation element in the center and on the right.

37. Install the engine cover and press the plugs in.

38. Connect the negative (–) battery cable.

CAUTION

Activate the automatic high-position function of the electric window regulator, and set the clock and enter the radio code; refer to the subsection Removing and Installing the Battery.