Electrical Equipment - General Information: Overview Audi S8 D3 facelift

Battery, General Information

The battery is one of the most important electrical components in the modern automobile. A battery that provides trouble-free service has a great influence on customer satisfaction. To ensure trouble-free service and optimum service life, batteries must be checked, serviced and maintained as per the instructions in this article.

Apart from starting the engine, the battery has other tasks. It acts as a buffer and also supplies electrical energy to the complete vehicle electrical system. In addition, the cyclical and capacity demands on the battery have increased due to additional safety and convenience features (electrical consumers) being installed.

The automobile battery has undergone many technical changes and improvements, and development of new battery technologies continues.

A new generation of maintenance free batteries uses physically and constructively optimized, lead-calcium coated positive electrodes. Advantages include minimal electrolyte consumption and servicing requirements, as well as improved charge stability over a longer period of time. Simplified checking of these batteries is also achieved with the "Magic Eye" charge indicator.

> Safety Precautions

> Lead-Acid Battery, Safety Precautions

Bosch Generator, from MY 2001, Assembly Overview

Note. The new generators are installed as a running change.

Scheme 427

1 - Generator (GEN)

2 - Voltage Regulator (VR)

1. Removing and installing --> «Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing»(ref-289230-S32698228382008062700000)
2. Carbon brushes, checking --> «Carbon Brushes, Bosch Generator from MY 2001, Checking»(ref-289230-S12777369182008062700000)

3 - Screw

1. 2.5 Nm

4 - Cover

5 - Nut

1. 12 Nm

6 - Nut

1. 30 Nm

7 - Screw

1. 3 Nm

8 - Screw

1. 1.5 Nm

Scheme 428

Removing

1. Remove generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-289227-S36040774962008062700000) .
2. Remove screw - 1 - and nuts - 3 - and - 4 -.
3. Remove cover - 2 - at rear side of generator.

Scheme 429

1. Remove screws - arrows -.
2. Remove voltage regulator.

Installing

1. When positioning voltage regulator, ensure carbon brushes rest correctly on slides.

Further installation is in reverse order of removal.

1. Tightening torque --> «Bosch Generator, from MY 2001, Assembly Overview»(ref-289230-S16844924252008062700000) .

Scheme 430

Procedure

1. Remove voltage regulator --> «Voltage Regulator, Bosch Generator from MY 2001, Removing and Installing»(ref-289230-S32698228382008062700000) .
2. Check carbon brushes for length - a -.

1. Wear limit: - a - = 5 mm.

Scheme 431

1 - Generator (GEN)

2 - Voltage Regulator (VR)

1. Removing

1. Remove nuts - item 5 - and cover - item 4 -.
2. Remove screw - item 6 - and nuts - item 7 - and remove voltage regulator.

1. Carbon brush wear limit: 5 mm

3 - Protective cap

4 - Cover

5 - Nut

1. 2 Nm

6 - Screw

1. 2 Nm

7 - Nut

1. Qty. 2
2. 3.5 Nm

Valeo Generator, from MY 2001, Assembly Overview

Note. The new generators are installed as a running change.

Scheme 432

1 - Generator (GEN)

2 - Voltage Regulator (VR)

1. Removing and installing --> «Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing»(ref-289230-S22665848592008062700000)
2. Carbon brushes, checking --> «Carbon Brushes, Valeo Generator from MY 2001, Checking»(ref-289230-S18268639652008062700000)

3 - Screw

1. 2 Nm

4 - Cover

5 - Protective cap

6 - Screw

1. 2 Nm

Scheme 433

Removing

1. Remove generator --> «27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL»(ref-289227-S36040774962008062700000) .
2. Press out cover from threaded pins at rear side of generator - arrows -.

Scheme 434

1. Remove bolts - 1 - and combination bolt - 2 -.
2. Remove voltage regulator.

Scheme 435

Installing

1. Press off protective cap - 2 - from voltage regulator - 1 - in - direction of arrow -.
2. When positioning voltage regulator, ensure carbon brushes rest correctly on slides.
3. Attach protective cap with voltage regulator installed.

Further installation is in reverse order of removal.

1. Tightening torque --> «Valeo Generator, from MY 2001, Assembly Overview»(ref-289230-S41003286932008062700000) .

Scheme 436

Procedure

1. Remove voltage regulator --> «Voltage Regulator, Valeo Generator from MY 2001, Removing and Installing»(ref-289230-S22665848592008062700000) .
2. Check carbon brushes for length - a -.

1. Wear limit: - a - = 5 mm.

Vehicle Electrical System, General Information

Note. If possible, do not loosen ground (GND) straps from body (danger of corrosion). Further information, e.g. installing and removing the individual components, is described in the appropriate article.

Wiring Harness and Connector Repairs, General Information

Note. Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information . Not all of the wire cross sections contained in the vehicle are in the Wiring Harness Repair Kit VAS 1978 or Wiring Harness Repair Set VAS 1978A. If the required wire cross-section is not present, the next greater cross-section must be used. For repairs on vehicle electrical system, soldering is not permitted. Do not repair crimp connectors. If necessary, lay a wire parallel to the faulty wire.

1. After crimping, crimp connections must be heat-shrunk using hot air gun to prevent moisture penetration.
2. Shielded wires, such as RPM sensors and knock sensors, may not be repaired. If faulty, the entire harness must be replaced.
3. Exclusive use is to be made of yellow wires for wiring harness repairs.
4. Wiring harness repairs should not be made again in the wrapping on the vehicle-specific wiring harness.

1. Mark repaired areas using yellow adhesive tape.
2. Yellow wires and areas in the wiring harness wrapped with yellow adhesive tape mark a previously performed repair.
3. Perform a function test after each repair. If necessary, check DTC memory, erase and/or bring systems into basic setting.

Terminal Housing and Harness Connector Repairs, General Information

Note. Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information . Allocation of crimp contacts with correct fit to contact housing is performed according to the part number stamped in on the contact housing. Terminal housing part numbers in conjunction with the appropriate crimp contacts. Damaged contact housings must always be replaced.

Scheme 437

Procedure

1. First, open or release secondary lock of the contact housing (where applicable) --> «Terminal Housings, Releasing and Disassembling»(ref-289230-S24003173572008062700000) .
2. Release contact (primary lock) using appropriate release tool - A - --> «Terminal Housings, Releasing and Disassembling»(ref-289230-S24003173572008062700000) .
3. Pull contact back out of housing - arrow - at single wire (with single wire seal if necessary).

Scheme 438

1. Cut off old contact (with the single wire seal) from vehicle-specific wiring harness.
2. Determine yellow repair wire with correct contact from Wiring Harness Repair Set VAS 1978A.
3. Free up wire to be repaired approximately 20 cm on both sides of the repair point.

1. If necessary, remove wiring harness wrapping using knife.

Scheme 439

1. Slide new repair wire contact into corresponding contact housing compartment until it engages.
2. If necessary, install single wire seal on repair wire --> «Single Wire Seals, Assembly»(ref-289230-S27022375822008062700000) .

1. Shorten repair wire and vehicle-specific wiring harness single wire as needed using the Wire Stripper VAS 1978/3.
2. Remove insulation from ends of repair wire and vehicle-specific single wire and crimp ends with crimping wires and a crimp connector --> «Wire, 0.25 mm with Individual Crimp Connector, Repairing»(ref-289230-S23702615522008062700000) or --> «Wire, 0.35 mm or Larger with Intermediate Wire Section, Repairing»(ref-289230-S24287485212008062700000) .

Terminal Housings, Release and Disassembly, General Information

Note. Observe general notes for repairs on the vehicle electrical system --> Vehicle Electrical System, General Information . Always use the release tools intended for the releasing process. Under no circumstances may terminals be pulled forcefully out of terminal housings. Damaged contact housings must always be replaced. Small screwdrivers may be used as an aid to release the secondary locks.

1. Chamber/pin assignment is located partially stamped in on secondary lock or rear side of terminal housing.
2. Detailed information on component locations of harness connectors --> Electrical Wiring Diagrams, Troubleshooting and Component Locations.
3. Allocation of the correct release tool to the respective retainers --> VAS 1978/35 instructions.