Generators & Regulators Audi S6 C5

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DESCRIPTION

Bosch alternators are conventional 3-phase, self-rectifying type alternators. Bosch voltage regulators are transistorized and integral with alternator. Voltage regulators are serviceable. Manufacturer recommends replacing generator as an assembly if defect is found.

BELT TENSION

Serpentine belt tension is automatically adjusted by tensioner.

DRIVE BELT ROUTING

Note. Serpentine belt is self-adjusting. For drive belt routing (Scheme 7)- (Scheme 9).

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PRELIMINARY INSPECTION

Verify customer complaint by operating system. Visually inspect for obvious signs of mechanical and electrical damage. Check generator belt tension and condition. Ensure that battery voltage is within specifications. Following manufacturers instructions for load tester, load test battery. See LOAD TEST under ON-VEHICLE TESTING. Inspect for blown fuses and damaged relays. For fuse and/or relay identification, see WIRING DIAGRAMS .

Verify ground connection integrity between engine, body, battery and generator. Check for damaged wiring harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, check for conditions that might cause an intermittent situation.

LOAD TEST

Note. If using VAS (1979) or VAS (5033), it is not necessary to remove battery from vehicle, or disconnect battery terminals.

Turn ignition to OFF position. Following tester manufacturer instructions, connect tester cable clamps to battery terminal. Ensure clamps make good contact with battery terminals. Load test battery at approximately one-half cold-cranking amperage rating for 15 seconds while observing battery voltage. If voltage reading is 9.5 volts or more, battery is okay. If voltage reading is less than 9.5 volts, charge battery and retest. If loaded battery voltage is still less than 9.5 volts after charging battery, replace battery.

NO LOAD TEST

Note. If no load voltage is to be measured with battery installed in vehicle, first disconnect ground strap.

Note. Vehicle must not be started or driven with tested battery for at least 2 hours before taking measurements. During this time, DO NOT allow load or additional charge to be applied to battery.

With battery installed, and ignition switched to OFF position, check voltage between battery terminals with voltmeter. If no load voltage is 12.5 volts, or higher, battery is okay. If no load voltage is lower than 12.5, recharge battery, and repeat procedure. If battery voltage is still less than 12.5 after charging battery, replace battery.

BRUSHES

Remove generator. See GENERATOR under REMOVAL & INSTALLATION. Remove voltage regulator from back of generator. See VOLTAGE REGULATOR under REMOVAL & INSTALLATION. Brushes are integrated with voltage regulator. Brush wear limit is 0.2" (5 mm).

REMOVAL & INSTALLATION

Air Bag

ECM

If connector is disconnected from ECM or battery is disconnected, all adaptation values in control module are erased. To achieve optimal anti-theft protection for vehicle, an anti-theft immobilizer was installed. Anti-theft immobilizer is a system for enabling/locking Engine Control Module (ECM) through the W-wire.

This system cannot be circumvented, it is necessary to perform adaptation of anti-theft immobilizer using VAS 5052 in On Board Diagnostic function. The great availability of equipment options makes adaptation of ECM necessary (e.g. cruise control system). This "writing" function is not possible with a generic scan tool, therefore it is necessary to use VAS 5052 in On Board Diagnostic function for this purpose. DTC memory content will remain intact however. If engine is started after this, a rough, uneven idle can result. In this case, ECM readiness code must be regenerated.

ECM Readiness Code

While limited diagnostic information is available, vehicle manufacturer does not support diagnostic information using aftermarket scan tools. To properly diagnose vehicle, it is recommended to use VAS 5051 scan tool with VAS 5051/1 adapter cable or VAG 1551 scan tool with 1551/3A adapter cable and VAG 1598/31 test box.

Readiness code must be generated when Engine Control Module (ECM) memory is cleared, battery voltage is disconnected or ECM is disconnected. To generate readiness code, vehicle must be stationary, transmission in Park or Neutral, all electrical consumers off, A/C switched off and coolant temperature at least 176° F (80° C). If possible, it is best to warm-up vehicle by test driving. Connect scan tool to DLC. DLC is located behind cover under left side of steering column.

Power Windows

After connecting battery, completely open and close all power windows.

Radio

Vehicles are equipped with an anti-theft stereo system that requires a code to activate. Record stereo code BEFORE disconnecting negative battery cable. Disconnect negative battery cable. Turn ignition to ON position. Reconnect negative battery cable. Enter code into stereo and reset clock.

Telematics

Telematics is an in-vehicle communication system that uses cellular, internet and Global Positioning System (GPS) technologies to provide customer with safety, security and convenience services. On vehicles equipped with Audi Telematics by OnStar®, switch emergency battery for telematic/telephone control module to the OFF position prior to disconnecting vehicle battery. Emergency battery is turned on and off using VAG 1551/VAG 1552 or VAS 5051/VAS 5052 scan tool in address word 75 - TELEMATICS set to function 10 - ADAPTATION CHANNEL 08.

Removal & Installation (2.7L - APB & BEL)

1. Remove battery cover. Disconnect negative battery terminal. Remove air intake channel bolts (1). (Scheme 10) 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»(/audi/s6/c5-1999-2004/remont/exterior-body-panels/#body-front__lock-carrier-with-attachments-removing-and). Remove noise insulation panel. (Scheme 11)
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 12) 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 13) 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 14) Remove terminal 30/B+ nut (1) from generator. Remove terminal D+ (2).
6. Unbolt coolant line retaining clamp (1) above torque support. (Scheme 15) Cut starter and generator wire cable ties (2), and open bracket (1). (Scheme 16) Remove wire.
7. Unbolt torque support (1). (Scheme 17) 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 18) Pull generator (4) down and remove.
9. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications). Ensure belt is installed in correct direction, and is installed correctly in sequence. (Scheme 7) Start engine, and check path of belt.

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Removal & Installation (3.0L - AVK)

1. Remove battery cover. Disconnect negative battery terminal. Remove air intake channel bolts (1). (Scheme 10) 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»(/audi/s6/c5-1999-2004/remont/exterior-body-panels/#body-front__lock-carrier-with-attachments-removing-and). Remove noise insulation panel. (Scheme 11)
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 12) 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 13) 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 19) Pull charge air cooler (intercooler) hose (2) down and remove.
6. Remove Terminal 30/B+ nut (2) from generator. (Scheme 20) Remove terminal D+ (1) from generator.
7. On vehicles equipped with automatic transmission, loosen ATF line bolt (1). (Scheme 21) 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 22) 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. (Scheme 7) Start engine, and check path of belt. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications).

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

1. Remove battery cover. Disconnect negative battery terminal. Remove noise insulation panel (arrows). (Scheme 11) Unbolt A/C coolant line bracket (arrow). (Scheme 23)
2. Using 17 mm box-head wrench, swing belt tensioner in direction of arrow. (Scheme 24) 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 25) Remove nut and eyelet terminal 30/B+ (2) from generator. (Scheme 26) 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 27) 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. (Scheme 8) Start engine, and check path of belt. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications).

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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 28)
2. Using box-head wrench, swing serpentine belt tensioner in direction of arrow. (Scheme 29) Swing until tension on belt is released. Insert Drift (3204) into alignment bore, to lock tensioner. (Scheme 30) Remove belt from generator belt pulley.
3. Position oil catch tray under engine in area of oil line. Separate oil line (1). (Scheme 31) Remove bolts (2 and 3). Remove oil line retaining clip.
4. Remove charge air cooler (intercooler) hose (arrows). (Scheme 32) Remove terminal 30/B+ nut (2) and eyelet from generator. (Scheme 33) Disconnect electrical connection (1) from D+ terminal.
5. Remove generator mounting bolts (arrows). (Scheme 34) 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 (Scheme 9)
7. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications). Check and refill engine oil if necessary. Start engine and check path of belt.

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Removal & Installation (With Freewheel)

1. Remove generator. See «GENERATOR»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators). Using Adapter (3400), counter-hold securing nut. (Scheme 35) Turn generator shaft clockwise to remove.
2. To install, turn generator shaft counterclockwise. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications). Clip protective cap onto freewheel pulley.

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Removal & Installation (Without Freewheel)

1. Remove generator. See «GENERATOR»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators). Using Socket (3310), counter-hold securing nut. (Scheme 36) Turn generator shaft clockwise to remove.
2. To install, turn generator shaft counterclockwise. Tighten to specification. See «TORQUE SPECIFICATIONS»(/audi/s6/c5-1999-2004/remont/charging-system/#generators-regulators__torque-specifications).

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VOLTAGE REGULATOR

Note. Manufacturer does not provide specific procedures for removal and installation of voltage regulator. As an aid in removal and installation (Scheme 37)

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OVERHAUL

Note. Manufacturer recommends replacing generator as an assembly. Overhaul procedures are not available.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

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WIRING DIAGRAMS

Note. See CHARGING SYSTEM in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

See also:
• LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING
• LOAD TEST
• WIRING DIAGRAMS
• GENERATOR
• VOLTAGE REGULATOR
• TORQUE SPECIFICATIONS