The power of the generator is indicated on the rating plate.
Attention! If additional electrical equipment is installed, then it is necessary to check whether the power of the existing generator is sufficient. If necessary, install a more powerful generator.
The generator produces alternating current, but since the battery can only be charged with direct current, the three-phase current is converted by a rectifier located on the diode board into direct current. The voltage regulator changes the charge current according to the degree of discharge of the battery by turning the excitation current on and off.
At the same time, the voltage regulator maintains a constant operating voltage (about 14V), regardless of the generator speed.
When working on the generator, certain precautions must be followed to prevent damage to the electrical system.
Be sure to disconnect the wire terminal before starting work on the electrical system «masses» (-) from the negative pole of the battery.
Attention! This removes the recorded information from some devices, and the security code from the radio, as well as all automatic settings on the radio. Therefore, before disconnecting the battery, the access code must be clarified and noted down. Otherwise, the radio can be put into operation only with the assistance of a representative of the manufacturer or an AUDI workshop. It is also recommended to write down the radio settings of the radio station.
Do not disconnect the battery or voltage regulator while the engine is running.
Do not remove the alternator with the battery connected.
Disconnect the battery when performing welding work on the vehicle.
Withdrawal
1. Disconnect the wire terminal «masses» (-) from the negative pole of the battery.
2. Drain the coolant.
3. Remove the front bumper (see relevant chapter).
Cars with petrol 8-cylinder engine
4. Set the upper cross member of the bulkhead to the service position.
5. Disconnect the plug 3 from the canister purge solenoid valve 2 and carefully remove the valve from the holder (see illustration).
10.5. Disconnect plug 3 from canister purge solenoid valve 2. Cars with petrol 8-cylinder engine
6. Disconnect plug 4 of the mass air flow sensor (see illustration 10.5).
7. Carefully disconnect hose 1 of the afterburner pump (see illustration 10.5).
8. Disconnect the air duct by loosening the clamp 5 (see illustration 10.5).
9. Remove the bolt (see arrow in illustration 10.5) and remove the air filter housing.
10. Disconnect the coolant hoses by loosening clamps 1 and 2 (see illustration).
10.10. Disconnect the coolant hoses by loosening clamps 1 and 2 (The illustration shows the engine removed). Cars with petrol 8-cylinder engine
11. Place a drip pan or suitable container under the engine to collect any remaining coolant.
12. Disconnect the coolant hose going to the oil cooler by removing the clamp (see arrow in illustration).
10.12. Disconnect the coolant hose going to the oil cooler by removing the clamp (see arrow). Cars with petrol 8-cylinder engine
13. Disconnect the cooling system hoses by loosening the corresponding fastening clamps (see arrows in illustration).
10.13. Disconnect the cooling system hoses by loosening the appropriate fastening clamps (see arrows). Cars with petrol 8-cylinder engine
14. Remove a collar 1 fastenings of a hose of a cooling liquid to the thermostat case (see illustration 10.13) and remove the hose. Move the rest of the coolant hoses away from the job site.
15. Cars with an afterburning system. Disconnect the hoses from the pump housing of the afterburning system by loosening the fastening clamps 3 and 4 (see illustration).
10.15. Disconnect the hoses from the afterburner pump housing by loosening the fastening clamps 3 and 4. Cars with an 8-cylinder engine and an afterburner system
16. Cars with an afterburning system. Disconnect plug 1, unscrew nuts 2 and 5 and remove the afterburning system pump from the bracket (see illustration 10.15).
17. Unscrew the nut (see arrow) and disconnect the wire «masses» (-) from the spar (see illustration).
10.17. Unscrew the nut and disconnect the wire terminal «masses» (-) from the spar. Cars with petrol 8-cylinder engine
18. Remove the bolt (see arrow in illustration) holder that secures the oil line to the bottom of the oil pan.
10.18. unscrew the bolt (see arrow) holder that secures the oil line to the bottom of the oil pan. Cars with petrol 8-cylinder engine
19. Remove the bolt (see arrow in illustration) and carefully remove the alternator drive belt (see relevant chapter).
10.19. unscrew the bolt (see arrow) and carefully remove the alternator drive belt. Cars with petrol 8-cylinder engine
Attention! Before removal, mark the direction of rotation of the alternator drive ribbed belt. If the old belt is installed against the direction of its rotation, this will lead to its premature wear and tear.
20. Remove the bolts (see arrows in illustration) fasteners and remove the alternator drive belt tensioner.
10.20. Unscrew the bolts (see arrows) fasteners and remove the alternator drive belt tensioner. Cars with petrol 8-cylinder engine
21. Remove the bolts (see arrows in illustration) generator mounts.
10.21. Unscrew the bolts (see arrows) generator mounts. Cars with petrol 8-cylinder engine
Attention! If the alternator is clamped in the bracket, then screw in the alternator mounting bolts about two turns again and gently tap the bolt heads with a hammer to unlock the alternator mounting bolt bushings.
22. Disconnect the coolant hose from the generator by removing the clamp 3, disconnect the plug 1, unscrew the nut 2 of the generator wire terminal (see illustration) and carefully remove the alternator.
10.22. Disconnect the coolant hose from the generator by removing the clamp 3, disconnect the plug 1, unscrew the nut 2 of the generator wire terminal. Cars with petrol 8-cylinder engine
Cars with a petrol 6-cylinder engine
23. Remove the accessory drive ribbed belt from the alternator pulley (see relevant chapter).
24. Loosen clamps 1 and remove hose 2 going to the intercooler (see illustration).
10.24. Loosen clamps 1 and remove hose 2 going to the intercooler. Cars about petrol 6-cylinder engine
25. Disconnect the wire connected to terminal 30 / V + of the generator by unscrewing the nut 2 of the terminal (see illustration).
10.25. Disconnect the wire connected to terminal 30/V+ of the generator by unscrewing the nut 2 of the terminal. Cars with a petrol 6-cylinder engine
26. Disconnect the wire from terminal 1 D+ of the generator by unscrewing the appropriate nut (see illustration 10.25).
27. Cars with automatic transmission. Unscrew the nut 1 of the holder of the transmission fluid circulation pipelines (see illustration).
10.27. Unscrew a nut 1 of the holder of pipelines of circulation of transmission liquid. Cars with a petrol 6-cylinder engine and automatic transmission
28. Unscrew the nut 2 of the refrigerant circulation pipe holder, then unscrew the bolts 3, loosen the clamp 4 and disconnect the pipe 5 (see illustration 10.27).
29. Unscrew the bolts 1 and 2 fastening the generator and carefully remove the generator by moving it down (see illustration).
10.29. Unscrew bolts 1 and 2 fastening the generator. Cars with a petrol 6-cylinder engine
Attention! If the alternator is clamped in the bracket, then screw in the alternator mounting bolts about two turns again and gently tap the bolt heads with a hammer to unlock the alternator mounting bolt bushings.
Diesel vehicles
30. Remove the cover 2 of the air filter together with the air intake 1 (see illustration).
10.30. Remove the cover 2 of the air filter together with the air intake 1. Cars with a diesel engine
31. Remove the bolts (see arrows in illustration) fasteners and remove the top protective cover of the engine.
10.31. Unscrew the bolts (see arrows) fasteners and remove the top protective cover of the engine. Diesel vehicles
32. Cars with a parking heater. Unscrew the bolts (see arrows in illustration) fastening the parking heater pipe to the soundproof panel.
10.32. Unscrew the bolts (see arrows) fastening the parking heater pipe to the soundproof panel. Vehicles with diesel engine and parking heater
33. Unscrew the bolts and wring out the clamps 1-3 and 5 and remove the engine mudguard (see illustration).
10.33. Unscrew the bolts / wring out the clamps 1-3 and 5 and remove the engine mudguard. Diesel vehicles
34. Remove the front bumper (see relevant chapter).
35. Remove the accessory drive ribbed belt from the alternator pulley (see relevant chapter).
36. Disconnect the wire from terminal 1 30 / V + of the generator by unscrewing the appropriate fastening nut (see illustration).
10.36. Disconnect the wire from terminal 1 30/V+ of the generator by unscrewing the appropriate fastening nut. Diesel vehicles
37 Disconnect the wire from terminal 2 D+ of the generator by unscrewing the appropriate fastening nut (see illustration 10.36).
38. Disconnect the plug from terminal 3 DF (see illustration 10.36).
39. Unscrew bolts 1 and 2 fastening the generator (see illustration).
10.39. Unscrew bolts 1 and 2 fastening the generator. Diesel vehicles
Attention! If the alternator is clamped in the bracket, then screw in the alternator mounting bolts about two turns again and gently tap the bolt heads with a hammer to unlock the alternator mounting bolt bushings.
40. Disconnect the plug (see arrow in illustration) hydraulic engine mount and remove the alternator by moving it downwards.
10.40. Disconnect the plug (see arrow) hydraulic engine mount and remove the alternator
Installation
The generator is installed in the reverse order of removal.
Alternator carbon brushes - check
41. Remove the voltage regulator (see relevant chapter).
42. Measure your length «A» generator brushes (see illustrations 10.42 and 10.42a). The permissible residual length of the brushes is 5 mm.
10.42. Measure length «A» generator brushes. Bosch generator | 10.42a. Measure length «A» generator brushes. Alternator Valeo |
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