Generators & Regulators: Removal & Installation Audi A6 C5 facelift

REMOVAL & INSTALLATION

Removal & Installation (2.7L - APB & BEL)

1. Remove battery cover. Disconnect negative battery terminal. Remove air intake channel bolts (1). (Scheme 8) Pull up on rear of intake channel (2).
2. Bring lock carrier into service position. For lock carrier procedures, see «LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING»(ref-196278-S04365420232005100800000). Remove noise insulation panel. (Scheme 9)
3. On vehicles equipped with tension roller with hex socket bolt, use 17 mm box-head wrench to swing belt tensioner in direction of upper arrow. (Scheme 10) Swing bolt until tension is released on serpentine belt. Insert Drift (3204) into alignment bore (lower arrows), to lock tensioner.
4. On vehicles equipped with tension roller with socket head bolt, use 10 mm socket head wrench to swing belt tensioner in direction of arrow. (Scheme 11) Swing bolt until tension is released from serpentine belt. Insert Drift (3204) into alignment bore (1 and 2), to lock tensioner.
5. On all vehicles, remove serpentine belt. Remove air guide (3) at generator. (Scheme 12) Remove terminal 30/B+ nut (1) from generator. Remove terminal D+ (2).
6. Unbolt coolant line retaining clamp (1) above torque support. (Scheme 13) Cut starter and generator wire cable ties (2), and open bracket (1). (Scheme 14) Remove wire.
7. Unbolt torque support (1). (Scheme 15) Unbolt torque support stop (2). Unbolt coolant line bracket. On vehicles equipped with an electrical coolant pump, unbolt and remove.
8. Remove generator mounting bolts (1 and 3). (Scheme 16) Pull generator (4) down and remove.
9. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000). Ensure belt is installed in correct direction, and is installed correctly in sequence. see scheme 7 Start engine, and check path of belt.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Removal & Installation (3.0L - AVK)

1. Remove battery cover. Disconnect negative battery terminal. Remove air intake channel bolts (1). (Scheme 8) Pull up on rear of intake channel (2).
2. Bring lock carrier into service position. For lock carrier procedures, see appropriate procedure under For lock carrier procedures, see «LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING»(ref-196278-S04365420232005100800000). Remove noise insulation panel. (Scheme 9)
3. On vehicles equipped with tension roller with hex socket bolt, use 17 mm box-head wrench to swing belt tensioner in direction of upper arrow. (Scheme 10) Swing bolt until tension is released on serpentine belt. Insert Drift (3204) into alignment bore (lower arrows), to lock tensioner.
4. On vehicles equipped with tension roller with socket head bolt, use 10 mm socket head wrench to swing belt tensioner in direction of arrow. (Scheme 11) Swing bolt until tension is released from serpentine belt. Insert Drift (3204) into alignment bore (1 and 2), to lock tensioner.
5. On all vehicles, remove serpentine belt from generator belt pulley. Remove hose clamps (1). (Scheme 17) Pull charge air cooler (intercooler) hose (2) down and remove.
6. Remove Terminal 30/B+ nut (2) from generator. (Scheme 18) Remove terminal D+ (1) from generator.
7. On vehicles equipped with automatic transmission, loosen ATF line bolt (1). (Scheme 19) On all vehicles, loosen A/C line bolt (2). Remove bolts (3) and loosen hose clamp (4). Remove tube (5).
8. Remove bolts (1). (Scheme 20) Remove socket head bolt (2). Pull generator down and remove.
9. To install, reverse removal procedure. Ensure belt is installed in correct direction, and is installed correctly in sequence. see scheme 7 Start engine, and check path of belt. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000).

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Removal & Installation (4.2 - AWN, BBD & BAS)

1. Remove battery cover. Disconnect negative battery terminal. Remove noise insulation panel (arrows). (Scheme 9) Unbolt A/C coolant line bracket (arrow). (Scheme 21)
2. Using 17 mm box-head wrench, swing belt tensioner in direction of arrow. (Scheme 22) Swing bolt until tension is released on serpentine belt. Insert Drift (3204) into alignment bore, to lock tensioner. Remove belt from generator belt pulley.
3. Remove air guide (arrow) from generator. (Scheme 23) Remove nut and eyelet terminal 30/B+ (2) from generator. (Scheme 24) Unscrew terminal D+1 nut (1). Disconnect electrical connection (3) from terminal DF. Unbolt line retainer (4) from engine mount.
4. Remove generator mounting bolts (arrows). (Scheme 25) Pull generator (1) down and remove.
5. To install, reverse removal procedure. Ensure belt is installed in correct direction, and is installed correctly in sequence. see scheme 8 Start engine, and check path of belt. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000).

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Removal & Installation (4.2 - BCY)

Note. Servicing of generator can be made easier by removing front bumper and moving lock carrier assembly away from engine. For bumper removal and lock carrier procedures, For lock carrier procedures, see LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING .

1. Remove battery cover. Disconnect negative battery terminal. Remove noise insulation panel. (Scheme 26)
2. Using box-head wrench, swing serpentine belt tensioner in direction of arrow. (Scheme 27) Swing until tension on belt is released. Insert Drift (3204) into alignment bore, to lock tensioner. (Scheme 28) Remove belt from generator belt pulley.
3. Position oil catch tray under engine in area of oil line. Separate oil line (1). (Scheme 29) Remove bolts (2 and 3). Remove oil line retaining clip.
4. Remove charge air cooler (intercooler) hose (arrows). (Scheme 30) Remove terminal 30/B+ nut (2) and eyelet from generator. (Scheme 31) Disconnect electrical connection (1) from D+ terminal.
5. Remove generator mounting bolts (arrows). (Scheme 32) Pull generator down, and remove.
6. To install, reverse removal procedure. Ensure belt is installed in correct direction. Install belt in the following sequence: Upper Idle Crankshaft Tensioning Roller Lower Idle Power Steering Pump A/C Compressor Generator see scheme 9
7. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000). Check and refill engine oil if necessary. Start engine and check path of belt.

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Removal & Installation (With Freewheel)

1. Remove generator. See «GENERATOR»(ref-164737-S19135538332004081600000). Using Adapter (3400), counter-hold securing nut. (Scheme 33) Turn generator shaft clockwise to remove.
2. To install, turn generator shaft counterclockwise. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000). Clip protective cap onto freewheel pulley.

Scheme 33

Removal & Installation (Without Freewheel)

1. Remove generator. See «GENERATOR»(ref-164737-S19135538332004081600000). Using Socket (3310), counter-hold securing nut. (Scheme 34) Turn generator shaft clockwise to remove.
2. To install, turn generator shaft counterclockwise. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-164737-S06134470932004081600000).

Scheme 34