AUDI A4 1998 B5 / 1.G Generator Workshop Manual

27-26


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.
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27-27

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.
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27-28


- 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.
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27-29


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.
- 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
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27-30

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-.
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27-31


Repair Manual, Body Exterior, Repair Group 63

Repair Manual, Body Exterior, Repair Group 50 - Remove noise insulation panel (arrows).
- Remove front bumper.
- Move lock carrier to service position.- 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.
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27-32

Vehicles with air conditioning
(Except 2.7 Liter/184 kW engine, 5V twin-turbo)

- Remove mounting clamp -1- for refrigerant lines above torque arm.
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27-33

2.7 Liter/184 kW engine, 5V Twin-turbo only

All vehicles - Remove air duct -1- (arrow).
- Remove charge air cooler on right -2- (loosen hose connection above,
mounted on three rubber supports).

- Detach cable for starter and generator from bracket -1-.
To do this, cut both tie wraps -2- open and then release the snap
catches.
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27-34


- 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)

CAUTION!
When removing the generator, be careful not to damage the
refrigerant lines. - 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.
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27-35

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
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