Audi A4. Body repair manual - part 67
Battery
Procedure for charging totally discharged,
sulfated batteries
Totally discharged, sulfated batteries must be
charged with a low charging current as follows:
- Set charging current to approximately 5% of
battery capacity, (e.g., for 60 Ah battery,
charging current should be about 3 amps).
Never fast-charge totally discharged batteries.
Note:
Once the battery is reconnected, check and
activate the vehicle's electrical equipment (radio,
clock, comfort and convenience features, etc.) as
described in this Repair Manual or the Owners
Manual.
Battery
Fast-charging/boost starting
Notes:
Batteries should be fast-charged (charging
current approximately 20% of battery capacity
and higher) only under exceptional
circumstances.
Batteries are damaged by fast-charging.
Boost starting is also possible using the
VAG1472 starter/charger.
The VAS1992 battery-starter provides boost
starting for vehicles with totally
discharged/weak batteries without connection
to line voltage. Depending on the outside
temperature and battery capacity, 15-30
starting operations can be completed.
Generator, removing and installing
Generator, removing and
installing
CAUTION!
Disconnect the battery Ground (GND) strap
before working on the electrical system.
Notes:
Before disconnecting the battery, determine the
correct coding for the anti-theft radio.
Once the battery is reconnected, check and
activate the vehicle's electrical equipment
(radio, clock, comfort and convenience
features, etc.) as described in this Repair
Manual or the Owners Manual.
Generator, removing and installing
Vehicles with 4-cylinder gasoline
engines
Removing
1.8 Liter/110 kW, 5V Turbo
- Disconnect air duct -1- for charge air cooler from throttle valve.
- Pivot ribbed belt tensioner in direction of arrow and remove ribbed belt
from generator pulley.
- Slowly release pressure on tensioner.
Generator, removing and installing
- Secure viscous clutch with 5 x 60 mm bolt and remove mounting bolt
for viscous clutch.
Tightening torque: 45 Nm (33 ft lb)
- Remove viscous clutch.
- Remove socket-head bolt -1-.
Tightening torque: 25 Nm (18 ft lb)
- Remove nut -2- from bolt.
Tightening torque: 45 Nm (33 ft lb)
- Pivot generator slightly to side and remove bolt from below.
Generator, removing and installing
- Release wiring harness from cable tie (arrow).
- Disconnect wire on terminal 30/B+ by removing nut -2-.
Tightening torque: 16 Nm (12 ft lb)
- Disconnect wire on terminal D+ by removing nut -1-.
Tightening torque: 4 Nm (35 in. lb)
- Carefully push radiator hose to side and lift generator up and out.
Installing
- To make it easier to install generator onto mount, drive bushing for
mounting bolt back approx. 1 mm.
- Install generator in reverse order of removal.
- Make sure ribbed belt is properly seated and correctly routed.
1 - Without air conditioning
2 - With air conditioning
Generator, removing and installing
Vehicles with 6-cylinder gasoline
engines
Special tools, test equipment and auxiliary
items
3204 drift
Removing
- Remove two bolts -1- on air intake duct and then lift up back portion of
air intake duct -2-.
Generator, removing and installing
- Remove noise insulation panel (arrows).
- Remove front bumper.
Repair Manual, Body Exterior, Repair Group 63
- Move lock carrier to service position.
Repair Manual, Body Exterior, Repair Group 50
- Remove cover for engine and ribbed belt.
- Rotate tensioner for ribbed belt toward right using box wrench until
both holes are in alignment (lower arrows), and secure in place using
3204 drift.
- Remove ribbed belt from generator pulley.
Generator, removing and installing
Vehicles with air conditioning
(Except 2.7 Liter/184 kW engine, 5V twin-turbo)
- Remove mounting clamp -1- for refrigerant lines above torque arm.
Generator, removing and installing
2.7 Liter/184 kW engine, 5V Twin-turbo only
- Remove air duct -1- (arrow).
- Remove charge air cooler on right -2- (loosen hose connection above,
mounted on three rubber supports).
All vehicles
- Detach cable for starter and generator from bracket -1-.
To do this, cut both tie wraps -2- open and then release the snap
catches.
Generator, removing and installing
- Disconnect air duct from generator fitting -3-.
- Disconnect wire on terminal 30/B + by removing nut -2-.
Tightening torque: 16 Nm (12 ft lb)
- Disconnect wire on terminal D+ by removing nut -1-.
Tightening torque: 4 Nm (35 in. lb)
- Remove socket head bolt -1- and lock nut -2-.
Tightening torque: 45 Nm (33 ft lb)
- Loosen bolt -3-.
Tightening torque: 22 Nm (16 ft lb)
- Remove generator -4- from below.
CAUTION!
When removing the generator, be careful not to damage the
refrigerant lines.
Generator, removing and installing
Installing
- To make it easier to install generator onto
mount, drive bushing for mounting bolt back
approx. 1 mm.
- Install generator in reverse order of removal.
- Make sure ribbed belt is properly seated and correctly routed.
1 - Without air conditioning
2 - With air conditioning
Generator, removing and installing
Voltage regulator, replacing
Model: Bosch
1 - Phillips-head screws
1 Nm (9 in. lb)
2 - Protective cover
3 snap catches
3 - Slotted screws
M4 = 2 Nm (18 in. lb)
4 - Voltage regulator
Removing and installing items - 1 -, - 2 -
and - 3 -
Wear limit for carbon brushes: 5 mm
5 - Generator