Audi 80/Avant (B4)

since 1991-1995 release

Repair and operation of the car

Audi 80/Avant
+ Technical specification
+ Engines
+ System of production of the fulfilled gases
+ Cooling system
+ Fuel tank and fuel pump
+ Air filter and airintaking channels
+ System of injection
+ Coupling
+ Transmission and transmission
+ Suspension bracket and steering
+ Brake system
+ Anti-blocking system of brakes
+ Wheels and tires
- Body electrical system
   Minus to "weight"
   Orientation in the electrical system
   Plug connections
   Central switchboard
   Additional block of the relay
   Relay and control units
   Unloading relay of contact of X
   Safety locks
   Table of safety locks
   Electric circuits
   + Full electroscheme of the Audi 80 car: 2-liter 4-cylinder engine (66 kW)
   + 2-liter 4-cylinder engine (85 kW)
   + 2,3-liter 5-cylinder engine (98 kW)
   + 2,6-liter 6-cylinder engine (110kvt)
   + Additional equipment
   + Battery
   - Generator
      Battery charging indicator
      Tension regulator
      Independent repair of the generator and regulator
   Check of a condition of a maple or polilinovy belt
   Tension of a maple belt
   Tension of a maple or poliklinovy belt
   The belt torn maple
   Engine overheat because of damage of a maple belt
   Review of maple and poliklinovy belts
   Replacement of a maple belt
   List of malfunctions
   List of malfunctions
+ System of ignition
+ Lighting
+ Signalling devices
+ Devices and auxiliary devices
+ Heating and ventilation
+ body Elements
+ Search of malfunctions
+ Specifications

Independent repair of the generator and regulator

For removal of a cover (2) generators of Bosch firm need to be turned out three screws with crosswise shliyets (1), to remove B+ wire from a carving bolt (3) and to wring out two fixing ledges (arrow).

The regulator of tension (2) fastens two bolts with crosswise shliyets (1). The position (3) designates a rotor axis.

On the removed tension regulator ((4) on an illustration the new design is shown) length of brushes (2) is designated by shooters. The position (1) shows contacts of the regulator of tension, (3) are fixing bolts.

On an illustration measurement of length of the sliding electrographite contacts at the removed regulator of tension of Bosch firm of older design is shown: brushes should not be shorter than and = than 5 mm.

Usually the generator does not demand repair, except cases of replacement of brushes of the generator. More serious damages cannot be eliminated with house means.

Check of tension of charging


  1. To attach volmetr between the plug of a thick red wire of the generator and "weight".
  2. To leave the engine to work at average turns.
  3. If the regulator of tension is serviceable, the voltmeter has to show 13,3 till 14,6 Century.
  4. If it not so to check brushes or to replace the regulator.
  5. Otherwise the generator is faulty.

Check of brushes


  1. To disconnect the negative plug of the battery.
  2. Generators of Bosch firm: to uncover on the accumulator behind (where is available).
  3. To disconnect the regulator from the generator. For this purpose to turn out two screws.
  4. To cast away the regulator in order that did not jam coal brushes in holders.
  5. To measure a vystupaniye of brushes.
  6. Length of new brushes is 13 mm; the minimum length is 5 mm.
  7. Generators of Valeo firm: to turn out both fixing screws of the regulator on the back party of the generator.
  8. To extend the regulator.
  9. To measure length of the acting brushes.
  10. If residual length made 5 mm – brushes are worn-out.
  11. Brushes of generators of Valeo firm cannot be got separately; it is necessary to change all regulator.

Replacement of brushes

Replacement of brushes on regulators of new generation of generators of Bosch firm is impossible now – therefore coal brushes are not on sale as spare parts now. If they wore out, it is necessary to change all regulator. The same can be told about the generator of Valeo firm; coal brushes are not on sale as the spare part – it is necessary to buy the new regulator of tension if brushes of the old wore out.

However at generators of Bosch firm of old generation similar replacement is possible. For this purpose the soldering iron, solder and, besides, knowledge of soldering will be required.


  1. To remove tension regulator according to the scheme described above.
  2. To unsolder multiwire flexible wires, to extend coal brushes.
  3. To remove press springs from old brushes and to put on the new.
  4. To solder multiwire flexible wires.
  5. Thus to apply a little tin and to work quickly in order that wires did not soak up a lot of tin. Otherwise they will become rigid.

 Podkazka: if brushes are removed, it is possible to check at the same time copper contact rings (on them brushes go). If on them scars extra earnings were found, it is necessary in a workshop after the auto electrician to grind them and to polish.

Removal of the generator


  1. To disconnect a wire of "weight" from the accumulator, otherwise danger of emergence of short circuit is great.
  2. Models with 4-cylinder engines: to uncover (where is available) a hinged bolt in front on a casing of a gear belt.
  3. Models with 5-cylinder engines: to remove the lower protection of a motor compartment.
  4. Models with 4-and 5-cylinder engines: to disconnect wires from the generator.
  5. To disconnect a cable to "weight" where is available.
  6. To turn out a tightening bolt on an adjusting level of the generator.
  7. To weaken and take off maple or poliklinovy a belt
  8. To weaken and remove a hinged bolt, holding thus the generator.
  9. Models with 6-cylinder engines: to remove the lower protection of a motor compartment.
  10. To take off maple a belt (the description of works is lower in this chapter).
  11. From below to remove a connecting wire and directing a stream of the cooling air.
  12. To weaken fixing bolts, to remove the generator.

The movement with faulty the generator

 Helps: if the generator or the regulator of tension do not work, it is still possible to continue a trip as a role of the power supply can assume the accumulator. In the afternoon of its stock of current lasts for a long time because electronic control by ignition/injection, and also to the electric fuel pump needs the minimum tension. Besides, often the battery is charged only on 2/3. Depending on the capacity of the battery it is possible to pass at least 5 more h. In the winter the complicating circumstance is the general weakness of the accumulator. Besides, it is necessary to include headlights earlier.

Therefore the economy of current has to become the motto: does not follow without need to interrupt a trip because the starter needs especially a lot of current. Whenever possible it is necessary to be got "from a setup". Not to include heating of back glass, an oven and radio. To handle a screen wiper more economically. To move without driving beam and fog lights at night. In addition to disconnect cables from the generator and to insulate separately in order that the accumulator could not be discharged via the faulty generator or the regulator of tension.