Think my Alternator has gone ? A4 2.5 V6

[MagicMat]

thanks for your input vwcabriolet1971

I was going to just throw another alternator on there because it was quick and easy. However i may actually pop down to my local Alternator place and see if they can test it.

[MagicMat]

Got the alternator off

its abit ackward to do, but once you have the front bumper off its not so bad.

tricky things were:
- taking the viscous (?) fan off
- having a 17mm allen key to move the tensioner (luckily i had a 17mm from doing the fork seals on my old Vmax)
- Also the M8 Bolts are a good call, while you could manage without them, it makes the job easier and keeps things inline.

GSF quoted me £185 inc VAT + £100 surcharge on an alternator.

However these are bascially just recon'd units.

So my local alternator specialist has had a look this morning. Showed me that oil has been dripping onto the alternator and has worn out the bushes in the alternator.

Im guessing this oil is coming from the cam cover on the left Vee (when looking at the engine from the front) So i need to repair this.

Options with the specialist are:

- Replace bushes and bearings at £35 (may last 6 months.. may last longer)
or
- Recon the unit at about £90

I dont really want to be taking the alternator off again in 6 months time so i'll probably just get it reconditioned. At least im saving about £100 that way.

Forgot to take photos as i took it off, (plus it was dark) but will try to take some when i put it back on.

[MagicMat]

Got my alternator reconn'ed for £90 including new internals and shot blasting.. including a warrenty.

which saved me about £100 over the GSF price for a recon'd unit !

the alternator is not fun to install at all ! but i got it back in.

I'll try to upload some pictures later, however if i forget and someone really wants to see them give me a nudge.

[robin_hackney]

I have a 2004 A4 Avant 2.5 TDI V6 which has also developed an alternator/charging error. I have just removed the alternator ready to get it tested repaired.
Based on the above post, here are some tips:
Specialist tools required:
2 * 32 mm open ended spanners (may be enough room to use 2 large adjustables).
1* 17mm allen/hex key (I made a tool by welding a 300mm handle onto a 100mm 17mm bolt)
4mm drill bit (to use as a locking pin for tensioner arm)

What to do:
Remove battery negative lead
Remove the silver top engine engine cover (pull upwards)
Remove the under engine tray (lots of straight screwdriver bolts/clips)
Remove the top 2 belt covers using the clips (the RHS cover has a clip hidden on the botton RHS - I used a stubby straight screwdriver to release it.
Remove the lower belt cover using 6mm allen/hex key - I used a mirror to find the 3 bolts, as all but 1 are hidden - The 6mm allen head is in the centre of a gold coloured 20mm disc (nut).
Remove the fan blade using 2*32mm spanners. Turn the spanner nearest the front of the car anti-clockwise. (removing this fan creates more room for you).
Remove air con belt (remove 13mm nut on tensioner pulley, and it will slacken loads)
Remove the alternator belt using the 17mm allen key to lever the tensioner anti-clockwise. This only slackened the belt by about 5mm, and it was a struggle to remove the belt - (you'll need a buddy to help hold the big allen key). Once the belt is off, you need to insert a 4mm locking pin (drill bit) into a hole 2" to the left of where the 17mm allen key is, and use it to lock the tensioner arm in place (otherwise it springs down a long way).
Remove the 2 bolts that secure the alternator (1*8mm allen bolt, 1*13mm hex bolt). I had to file a bit off the radiator grille to get the 8mm hex bolt out fully.
Drop the alternator out carefully, and remove the 2 electrical connectors.

[the_old_diver]

".. I'll probably make up some 100mm M8 bolts rather than buying a kit"

I removed all bolts except one on each side befrore inserting a length of correct diameter studding from B&Q in one hole on each side. With a nut on the studding you can then wind the front out as far as you need it. Just take care not to bark your shins on the rod too often :-)

Couple of quid...