Get Generator Guide for Audi A1 SUV 2010-2017

Audi A1 2011 ➤ , Audi A1 Sportback 2018 ➤ , Audi A2 2001 ➤ , Audi A3 20 ...

Electrical Equipment General Information - Edition 08.2019

4

Generator

⇒ “4.1 Generator, Checking”, page 59

⇒ “4.2 Overview - Generator, Bosch through MY 2000”,

page 60

⇒ “4.3 Overview - Bosch Generator from 2001”, page 62

⇒ “4.4 Voltage Regulator, Bosch Generator from 2001, Removing

and Installing”, page 63

⇒ “4.5 Overview - Bosch Generator from 2007”, page 63

⇒ “4.6 Voltage Regulator, Removing and Installing, Bosch Gen‐

erator from 2007”, page 64

⇒ “4.7 Carbon Brushes, Checking, All Bosch Generators from

2001”, page 65

⇒ “4.8 Overview - Generator, Valeo through MY 2000”,

page 65

⇒ “4.9 Overview - Valeo Generator from 2001”, page 67

⇒ “4.10 Voltage Regulator, Valeo Generator from 2001, Remov‐

ing and Installing”, page 68

⇒ “4.11 Carbon Brushes, Valeo Generator from 2001, Checking”,

page 68

⇒ “4.12 Voltage Regulator, Removing and Installing, Valeo Gen‐

erator from 2007”, page 69

⇒ “4.13 Carbon Brushes, Checking, Valeo Generator from 2007”,

page 69

⇒ “4.14 Ribbed Belt Pulley without Freewheel, Removing and In‐

stalling”, page 70

⇒ “4.15 Ribbed Belt Pulley with Freewheel, Removing and Instal‐

ling”, page 71

⇒ “4.16 Ribbed Belt Pulley with Freewheel, Checking”,

page 73

⇒ “4.17 Overview - Hitachi Generator”, page 73

⇒ “4.18 Voltage Regulator, Removing and Installing - Hitachi

Generator”, page 74

⇒ “4.19 Carbon Brushes, Checking, Hitachi Generator”,

page 75

4.1

Generator, Checking

⇒ “4.1.1 Generator C , Checking”, page 59

⇒ “4.1.2 Starter Generator C29 , Checking, 0K4 and VH0”, page

60

⇒ “4.1.3 Starter Generator C29 , Checking, 0K4 and VH2/VH3”,

page 60

4.1.1

Procedure

Generator - C- , Checking

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Connect the Vehicle Diagnostic Tester .

– Select the Diagnostic mode and start the diagnosis.

– Select the Test plan tab.

4. Generator

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– Select the Select individual test button and select the

following tree structure consecutively:

♦ 12V vehicle electrical system

♦ C - Generator - Test

– Start the selected program and follow the instructions on the

Vehicle Diagnostic Tester display.

4.1.2

Starter Generator - C29- , Checking,

0K4 and VH0

Procedure

– Connect the Vehicle Diagnostic Tester .

– Select the Diagnostic mode and start the diagnosis.

– Select the Test plan tab.

– Select the Select individual test button and select the

following tree structure consecutively:

♦ 12V vehicle electrical system

♦ C29 - Starter Generator, Checking

– Start the selected program and follow the instructions on the

Vehicle Diagnostic Tester display.

4.1.3

Starter Generator - C29- , Checking,

0K4 and VH2/VH3

Procedure

– Connect the Vehicle Diagnostic Tester .

– Select the Diagnostic mode and start the diagnosis.

– Select the Test plan tab.

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– Select the Select individual test button and select the

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

following tree structure consecutively:

♦ Diagnostic-capable systems

♦ 00CC - Starter Generator -C29-

♦ 00CC - Partial System Conditions

♦ C29 - Starter Generator, Checking

– Start the selected program and follow the instructions on the

Vehicle Diagnostic Tester display.

4.2

Overview - Generator, Bosch through MY 2000

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1 - Bolts

❑ 1 Nm

2 - Cover

❑ With three tabs

3 - Bolts

❑ 2 Nm

4 - Voltage Regulator

❑ Removing:

–

Remove the bolts -1-

and remove the protec‐

tive cap -2-.

–

Remove the bolts -3-

and remove the voltage

regulator.

❑ Carbon brushes wear

limit: 5 mm

5 - Generator

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Generator

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4.3

Overview - Bosch Generator from 2001

Note

The generators were implemented as a running change.

1 - Generator

2 - Voltage Regulator

❑ Removing and instal‐

ling. Refer to

⇒ “4.4 Voltage Regula‐

tor, Bosch Generator

from 2001, Removing

and Installing”,

page 63 .

❑ Carbon brushes, check‐

ing. Refer to

⇒ “4.7 Carbon Brushes,

Checking, All Bosch

Generators from 2001”,

page 65

3 - Bolt

❑ 2.5 Nm

4 - Cover

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

5 - Nut

❑ 12 Nm

6 - Nut

❑ 30 Nm

7 - Bolt

❑ 3 Nm

8 - Bolt

❑ 1.5 Nm

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4.4

Voltage Regulator, Bosch Generator

from 2001, Removing and Installing

Removing

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

– Remove the bolt -1- and the nuts -3 and 4-.

– Remove the cover -2- on the rear side of the generator.

– Remove the bolts -arrows-.

– Remove voltage regulator.

Installing

– When installing the voltage regulator, make sure the carbon

brushes rest correctly on the slip rings.

Install in reverse order of removal, observing the following:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

–^perI^mn^its^tet^da^ull^nlt^eh^sse^aug^the^on^rise^er^da^bt^yo^Ar^U.^DR^{I A}e^Gfe^{. A}r^Ut^Do^{I A}⇒^{G d}E^oel^seⁿc^ot^tr^gic^uaa^ralⁿE^teq^eu^orip^acm^cepe^tn^ant;^yR^liabe^ilp^ity.

with respect to the correctness of information in this document. Copyright by AUDI AG.

Gr. 27 ; Generator; Generator, Removing and Installing .

•

Tightening specification. Refer to

⇒ “4.3 Overview - Bosch Generator from 2001”, page 62 .

4.5

Overview - Bosch Generator from 2007

Note

The new generators are installed as a running change.

4. Generator

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1 - Nut

❑ 65 Nm

2 - Ribbed Belt Pulley

3 - Generator

4 - Voltage Regulator

❑ Removing and instal‐

ling. Refer to

⇒ “4.6 Voltage Regula‐

tor, Removing and In‐

stalling, Bosch Genera‐

tor from 2007”,

page 64 .

❑ Carbon brushes, check‐

ing. Refer to

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ “4.7 Carbon Brushes,

Checking, All Bosch

Generators from 2001”,

page 65

5 - Bolt

❑ 1.5 Nm

6 - Cover

7 - Bolt

❑ 3 Nm

8 - Bolt

❑ 2.5 Nm

4.6

Voltage Regulator, Removing and In‐

stalling, Bosch Generator from 2007

Removing

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

– Remove the bolts -arrows-.

– Remove the cover -1- on the rear side of the generator.

64

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– Remove the bolts -arrows-.

– Remove voltage regulator -1-.

Installing

– When installing the voltage regulator, make sure the carbon

brushes rest correctly on the slip rings.

Install in reverse order of removal, observing the following:

– Install the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

•

Tightening specification. Refer to

⇒ “4.3 Overview - Bosch Generator from 2001”, page 62 .

4.7

Carbon Brushes, Checking, All Bosch

Generators from 2001

Procedure

– Remove the voltage regulator: to 2007. Refer to

⇒ “4.4 Voltage Regulator, Bosch Generator from 2001, Re‐

moving and Installing”, page 63 , after 2007

⇒ “4.6 Voltage Regulator, Removing and Installing, Bosch

Generator from 2007”, page 64 .

– Check the length -a- of the carbon brushes.

•

Wear limit: -a- = 5 mm.

– Install the voltage regulator: to 2007. Refer to

⇒ “4.4 Voltage Regulator, Bosch Generator from 2001, Re‐

moving and Installing”, page 63 , after 2007

⇒ “4.6 Voltage Regulator, Removing and Installing, Bosch

Generator from 2007”, page 64 .

4.8

Overview - Generator, Valeo through MY 2000

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Generator

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1 - Generator

2 - Voltage Regulator

❑ Removing:

–

Remove the nuts -5-

and the cover -4-.

–

Remove the bolt -6- and

the nuts -7- and remove

the voltage regulator.

❑ Carbon brushes wear

limit: 5 mm

3 - Protective Cap

4 - Cover

5 - Nut

❑ 2 Nm

6 - Bolt

❑ 2 Nm

7 - Nut

❑ 3.5 Nm

❑ Quantity: 2

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

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4.9

Overview - Valeo Generator from 2001

Note

The generators were implemented as a running change.

1 - Generator

2 - Voltage Regulator

❑ Removing and instal‐

ling: to 2007. Refer to

⇒ “4.10 Voltage Regula‐

tor, Valeo Generator

from 2001, Removing

and Installing”,

page 68 , after 2007

⇒ “4.12 Voltage Regula‐

tor, Removing and In‐

stalling, Valeo Genera‐

tor from 2007”,

page 69

❑ Check the carbon

brushes: to 2007. Refer

to

⇒ “4.11 Carbon Brush‐

es, Valeo Generator

from 2001, Checking”,

page 68 , after 2007

⇒ “4.13 Carbon Brush‐

es, Checking, Valeo

Generator from 2007”,

page 69

3 - Bolt

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❑ 2 Nm

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4 - Cover

5 - Protective Cap

6 - Bolt

❑ 2 Nm

4. Generator

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4.10

Voltage Regulator, Valeo Generator

from 2001, Removing and Installing

Removing

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

– Press the cover on the rear side of the generator off of the

threaded pins -arrows-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

– Remove the bolts -1- and the double bolt -2-.

– Remove voltage regulator.

Installing

– Press the protective cap -2- off of the voltage regulator -1- in

direction of -arrow-.

– When installing the voltage regulator, make sure the carbon

brushes rest correctly on the slip rings.

– Install the protective cap with the voltage regulator installed.

Install in reverse order of removal, observing the following:

– Install the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

•

Tightening specification. Refer to

⇒ “4.9 Overview - Valeo Generator from 2001”, page 67 .

4.11

Carbon Brushes, Valeo Generator from

2001, Checking

Procedure

– Remove voltage regulator. Refer to

⇒ “4.10 Voltage Regulator, Valeo Generator from 2001, Re‐

moving and Installing”, page 68 .

– Check the length -a- of the carbon brushes.

•

Wear limit: -a- = 5 mm.

– Install the voltage regulator. Refer to

⇒ “4.10 Voltage Regulator, Valeo Generator from 2001, Re‐

moving and Installing”, page 68 .

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4.12

Voltage Regulator, Removing and In‐

stalling, Valeo Generator from 2007

Special tools and workshop equipment required

♦ Feeler gauge 0.3 mm

Removing

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

– Press the cover on the rear side of the generator off of the

threaded pins in direction of -arrows-.

– Remove the bolts -1- and the double bolt -2-.

– Remove voltage regulator.

Installing

– Push a feeler gauge 0.3 mm -4- between the protective cap

-2- and the carbon brushes -3-.

– Pull the protective cap off until the bar of the protective cap

presses the carbon brushes down.

– After installation of the voltage regulator, press the protective

cap all the way on.

Install in reverse order of removal, observing the following:

– Install the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

•

Tightening specification. Refer to

⇒ “4.9 Overview - Valeo Generator from 2001”, page 67 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4.13

Carbon Brushes, Checking, Valeo Gen‐

erator from 2007

Special tools and workshop equipment required

♦ Feeler gauge 0.3 mm

4. Generator

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Procedure

– Remove voltage regulator. Refer to

⇒ “4.12 Voltage Regulator, Removing and Installing, Valeo

Generator from 2007”, page 69 .

– Push a feeler gauge 0.3 mm -3- between the protective cap

-2- and the carbon brushes.

– Remove the protective cap from voltage regulator -1- in direc‐

tion of -arrow-.

– Check the length -a- of the carbon brushes.

•

Wear limit: -a- = 5 mm.

– With protective cap -2- installed, use feeler gauge -4- to press

carbon brushes -3- down.

– Push the protective cap off in direction of -arrow- until the bar

of the protective cap presses the carbon brushes down.

– Install the voltage regulator. Refer to

⇒ “4.12 Voltage Regulator, Removing and Installing, Valeo

Generator from 2007”, page 69 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4.14

Ribbed Belt Pulley without Freewheel,

Removing and Installing

Special tools and workshop equipment required

♦ Generator Belt Socket - 3310-

®

♦

Inner hex socket 8 mm or TORX T50

70

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Removing

– Remove the generator if necessary. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Generator; Generator, Removing

and Installing .

– For some engine types the removal can be performed with the

generator still installed, here only the ribbed belt must have

the tension released and be removed.

– If present, press the protective cap off the generator pulley.

– Counterhold nut using -3310- and rotate generator shaft clock‐

wise to loosen it.

– Remove ribbed belt pulley.

Installing

Install in reverse order of removal. Note the following:

– Turn the generator shaft counterclockwise to tighten.

– Clip protective cap onto generator pulley.

Tightening specification

Component

Nm

65

Ribbed belt pulley to generator

4.15

Ribbed Belt Pulley with Freewheel, Re‐

moving and Installing

Special tools and workshop equipment required

♦ Torque Wrench 1332 40-200Nm - VAG1332-

♦ Adapter - T10474-

♦ Multi-Tooth Adapter - 3400-

♦ Socket - 3400/1-

General Information

There are different ribbed belt pulley with freewheel.

Before removing check which special tool must be used for the

removal of the ribbed belt pulley with freewheel.

Caution

The length of the ribbed belt is different depending on the rib‐

bed belt pulley with freewheel installed.

Check which ribbed belt pulley with freewheel is installed and

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make sure that the correct ribbed belt will be installed. For the

ribbed belt allocation. Refer to the Pa^pr^ets^rmC^ittea^dt^uaⁿl^lo^esg^{s a}.^{uthorised by AUDI AG. AUDI AG does not guarantee or accept any liability}

with respect to the correctness of information in this document. Copyright by AUDI AG.

Characteristics of the Ribbed Belt Pulley with Freewheel

-A- small ribbed belt pulley with freewheel, special tool to be used

-T10474- or -3400/1-

4. Generator

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-B- large ribbed belt pulley with freewheel, special tool to be used

-3400-

Note

The ribbed belt for the large ribbed belt pulley with freewheel must

be larger because it has a larger diameter.

Removing

– Remove the generator if necessary. Refer to ⇒ Electrical

Equipment; Rep. Gr. 27 ; Generator; Generator, Removing

and Installing .

– For some engine types the removal can be performed with the

generator still installed, here only the ribbed belt must have

the tension released and be removed.

– Clamp the generator in a vise at the mounting points.

– If equipped, remove the protective cap from the decoupling

belt pulley with freewheel.

– Install the -T10474- or -3400- -1- in the belt pulley and attach

a wrench.

– Place a suitable tool -2- in the generator shaft.

– Turn the generator shaft clockwise in direction of -arrow- to

loosen and while doing so counterhold with the wrench.

– Hold the ribbed belt pulley_Pw_roi_tt_eh_ctefr_de_be_yw_coph_ye_rige_hl_t.in_Cop_pyl_ia_ngc_fe_orb_pry_ivah_tea_on_rd_coa_mn_md_{ercial purposes, in part or in whole, is not}

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

turn it at the generator shaft until the ribbed belt pulley with

with respect to the correctness of information in this document. Copyright by AUDI AG.

freewheel can be removed.

Installing

Install in reverse order of removal. Note the following:

The -VAG1332- must be rearranged for installing the decoupling

belt pulley with freewheel as follows:

– Release the insert -1- and remove it from the handle part -2-.

– Turn the handle part -2- of the torque wrench 180° and reinsert

the socket.

– Set the rotation direction of the torque wrench socket to "left".

– Next, screw the ribbed belt pulley with freewheel by hand onto

the generator shaft until stop.

– Install the -T10474- -1- ribbed belt pulley with freewheel and

attach the wrench.

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– Place a suitable tool -2- in the generator shaft.

– Turn the generator shaft using the -VAG1332- -3- counter

clockwise to tighten the ribbed belt pulley with freewheel.

– Clip protective cap onto generator pulley.

Tightening Specification

Component

Tightening

Specification

Ribbed belt pulley with freewheel to generator

80 Nm

4.16

Ribbed Belt Pulley with Freewheel,

Checking

Procedure

•

The ribbed belt pulley with freewheel is removed. Refer to

⇒ “4.15 Ribbed Belt Pulley with Freewheel, Removing and In‐

stalling”, page 71 .

– Hold the inner ring -2- on the ribbed belt pulley with one hand

using the thumb and index finger and the outer ring -1- with

the other hand using the thumb and index finger.

– Hold the inner ring tight and turn the outer ring in the rotation

direction of the generator.

•

If the free-running hub is intact, the outer does not turn.

– Hold the inner ring tight and turn the outer ring opposite the

rotation direction of the generator.

•

If the free-running hub in intact, the outer ring turns with slight

resistance.

Replace the ribbed belt pulley if the free-running hub does not

function as described.

4.17

Overview - Hitachi Generator

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permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4. Generator

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1 - Generator

2 - Screw

❑ 2 Nm

❑ Quantity: 4

3 - Voltage Regulator

❑ Removing and Instal‐

ling. Refer to

⇒ “4.18 Voltage Regula‐

tor, Removing and In‐

stalling - Hitachi Gener‐

ator”, page 74 .

❑ Carbon brushes, check‐

ing. Refer to

⇒ “4.19 Carbon Brush‐

es, Checking, Hitachi

Generator”, page 75

4 - Nut

❑ 4 Nm

❑ Quantity: 2

5 - Cover

6 - Screw

❑ 4 Nm

❑ Quantity: 6

7 - Protective Cap

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8 - Nut

❑ 11 Nm

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4.18

Voltage Regulator, Removing and In‐

stalling - Hitachi Generator

Special tools and workshop equipment required

♦ Torque Wrench 1410 - VAG1410-

♦ Torque Screwdriver - VAG1624-

Removing

– Remove the generator. Refer to ⇒ Electrical Equipment; Rep.

Gr. 27 ; Generator; Generator, Removing and Installing .

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– Remove the nut -2-.

– Remove the protective cap -3-.

– Remove the bolts -4-.

– Remove the cover -1-.

– Remove the screws -3-.

– Remove the nuts -2-.

– Remove the voltage regulator -1-.

Installing

Install in the reverse order of removal while noting the following:

– When installing the voltage regulator, make sure the carbon

brushes rest correctly on the slip rings.

– Install the generator. Refer to ⇒ Electrical Equipment; Rep.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Gr. 27 ; Generator; Generator, Removing and Installing .

permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

with respect to the correctness of information in this document. Copyright by AUDI AG.

4.19

Carbon Brushes, Checking, Hitachi

Generator

Procedure

– Remove the voltage regulator. Refer to

⇒ “4.18 Voltage Regulator, Removing and Installing - Hitachi

Generator”, page 74 .

– Check the length -a- of the carbon brushes -1-.

•

Wear limit: -a- = 6.5 mm.

– Install the voltage regulator. Refer to

⇒ “4.18 Voltage Regulator, Removing and Installing - Hitachi

Generator”, page 74 .

4. Generator

75

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Generator for Your Audi A1 SUV 2010-2017

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