48v battery and alternator issue RS6/7

[Nsd991]

I’m seeing a lot of posts where people have been stranded with this often abrupt and dreadful issue. Thankfully all of our cars are still under warranty. For those that have experienced this issue what was the repair cost (on the invoice, I know warranty cost is zero)? Is it worth buying an extended warranty from Audi assuming one plans to keep this car beyond the warranty period? Will the extended warranty even cover this issue? Should we disable and not use the start/stop function as a preventative measure?

[Astonished]

I’m seeing a lot of posts where people have been stranded with this often abrupt and dreadful issue. Thankfully all of our cars are still under warranty. For those that have experienced this issue what was the repair cost (on the invoice, I know warranty cost is zero)? Is it worth buying an extended warranty from Audi assuming one plans to keep this car beyond the warranty period? Will the extended warranty even cover this issue? Should we disable and not use the start/stop function as a preventative measure?

I know that there are a couple of other threads that discuss the alternator issue, however as this one mentioned the thought line I had with the stop/start system and it’s top of the threads I thought I’d run my question here:

Has anyone got any indicative, circumstantial, straw poll or other data that helps understand whether the turning off of the stop start system changed the likelihood of alternator failure?

Anyone who has had the alternator fail could respond with:

I turn off the stop/start
OR
I just let the car default to stop/start

I’m thinking, that based on the tsb generously provided by another member in the similar thread, that it’s more of a control/software issue, so maybe the stop/start system is irrelevant

Over to all you unfortunate owners who have experienced the death of an alternator

[F10TT]

Just had mine replaced. There's evidence of coolant intrusion.

Cost out of warranty would have been $5,300. It was covered under warranty.

[FBAnder]

Just had mine replaced. There's evidence of coolant intrusion.

Cost out of warranty would have been $5,300. It was covered under warranty.

Well that's a new wrinkle!

[kjcncsu]

Just had mine replaced. There's evidence of coolant intrusion.

Cost out of warranty would have been $5,300. It was covered under warranty.

That's actually less than I would have expected. Was there a breakdown of parts and labor?

[Corgiman30]

Just had mine replaced. There's evidence of coolant intrusion.

Cost out of warranty would have been $5,300. It was covered under warranty.

I got Audi’s most comprehensive extended warranty. I would expect this part to be covered.

[FBAnder]

My concern with coolant intrusion is I am not sure a software update is gonna stop it from happening again. If this issue is a potential repeat offender that can pop-up at any time, that is a hard "Oh hell no".

[Nsd991]

I got Audi’s most comprehensive extended warranty. I would expect this part to be covered.

Can this warranty be purchased now while still under warranty? If this issue is covered I may just buy the warranty. I’d hate to start over with new Akrapovic/ppf/ceramic etc....cheaper just to buy piece of mind if remotely thinking of keeping the car (only reason to keep is no replacement that excites me enough to switch).

[Corgiman30]

Can this warranty be purchased now while still under warranty? If this issue is covered I may just buy the warranty. I’d hate to start over with new Akrapovic/ppf/ceramic etc....cheaper just to buy piece of mind if remotely thinking of keeping the car (only reason to keep is no replacement that excites me enough to switch).

I believe so.

[robwrongshoes]

My alternator died, but I have my car set up to never turn off except when at a complete stop.

[OneFastBMW]

Has anyone with a 2022 had the belt starter generator die yet? I know the TSB is only up to 2021 and I wonder if there was a revision or they just haven’t updated it yet.

Also, for anyone curious, here is what I have found out on the 48v system in the RS6/RS7:

Quick background, volts multiplied by amps equals watts. Watts is a unit of power (like horsepower). A watt hour is a unity of capacity (like gallons of gasoline). 1 watt hour is the capacity to output 1 watt of power for one hour of time.

The 48v system is the only way to charge the 12v battery. The belt starter/generator (“BSG”) output 48v, nominally. The only 48v wires in the car go from the SAG to the 48v battery and then to the DC-DC converter located on top of the 12v battery, all in the rear luggage compartment. The DC-DC converter is the only way to charge the 12v battery and ALL vehicle systems are natively 12v. This is why when the SAG dies the whole car goes “caput” as the 12v battery is no longer getting charged.

The SAG actually does more than just the start/stop function, but not by much. While other car use the 48v architecture for active roll bars (SQ7, SQ8, RSQ8, etc) or for the suspension (S8), the RS6/7 just uses it for 2 things:
1) start/stop functionality (but not cold starts, that is handled by a traditional 12v starter on the flywheel at the rear of the engine).
2) Mild assistance for the gas engine. The SAG can provide up to 8hp of assistance for 5 seconds, or 6hp of assistance continuously. This assistance can be seen by logging the current going into the 48v battery. On hard acceleration you will see up to 120 amps out of the 48v battery pack. 48v multiplied by 120 amps equals 5,760 watts. 745 watts is one horsepower, so 5,760 divided by 745 is about 8hp.

The 12v batteries on these cars is relatively small at 68Ah, but as I mentioned the 12v battery is really just a “buffer” since the 48v battery recharges it via the DC-DC converter. At 12v and 68Ah the power stored in the 12v battery is 816Wh. The 48v battery has a capacity of “only” 9.6Ah, but this is at 48v, so the power stored in this battery is an additional 461Wh. With the two batteries combined, it is as if the vehicle had a 12v battery 105Ah in size, which is pretty normal for for a car this size with all the tech bells and whistles.

Hopefully in the future we will see the 48v system used for more, but right now the only “performance” attribute is the extra 8hp/6hp on the RS6/RS7.

[FBAnder]

I've seen a 22 RSQ8 on Audiworld report a 48V generator failure. So I do think the TSB will be superceded yet again at some point with the 22 MY added for some models.

[Djpeaksd]

2021 RS7, mine died at 16,000 miles and I never use auto start/stop. My service guy said he has 8 dead Audi's in the back with the same issue and they can't get the parts for them. He is pretty confident that this will turn into a full on recall.

[pwdrskr]

Has anyone with a 2022 had this problem? I looked at the TSB and it looks like it applies to 2021s only.

[FBAnder]

Hasanyone with a 2022 had this problem? I looked at the TSB and it looks like it applies to 2021s only.

Updated TSB: https://static.nhtsa.gov/odi/tsbs/20...22114-0001.pdf (oddly the RS 6 isn't listed but it definitely applies). From an Audiworld thread from an '21 RSQ8 owner (HDCL):

So here is a long update of my experience with Audi Service regarding the Electrical System Malfunction "Christmas Tree" error:

Back in April/May of 2022, I was idling in a parking lot and the S/S system kept cycling. It was a hot day, so the AC was running. After about 10 minutes, everything shut down and I got the various failure messages (Generator, 48V System, Active Differential, etc.) Shutting it down and restarting made the error go away. I did an OBD scan, and it showed a P065C00 - Generator Mechanical Performance - Intermittent fault.
The error never reoccurred, and I went on 2 long road trips in Nov/Dec (over 1,200 miles round trip) with no issues
I received the MMI backup camera recall notice and scheduled an appointment for Jan 2 at the Audi dealership. I informed them of the prior Generator error and code. They were aware of the TSB and have 5 vehicles awaiting a new generator that have completely failed. They agreed that at a minimum, the software update per TSB would probably be required.
On Jan 3, the service coordinator contacted me to get a screenshot of the OBD error code. Their scan revealed no error codes related to the generator or 48V system. There was one for the Active Differential. Audi Corporate was not giving them permission to just update the software with no error code, so they were trying to make a case for me. Due to people just coming back from the Holidays, there was some delay
Today (Jan 4), they informed me that they got the go ahead to flash the software, but when they tried to do it, the software version on the vehicle was already the version that the TSB was instructing to update to - hence no update done or required per Audi. At this point, there is nothing more that can be done from a preventative perspective. I am scheduled to go pick up the vehicle this afternoon. There will be a printout of the current software version installed (that matches the TSB) that I can try to upload here.


So, in summary, here are my key takeaways:

Audi does not seem keen to just flash the software as a preventative measure if there are no codes related to this error that they can use to justify the update
Your Service Coordinator is going to be the key in how this is handled for each of us individually. While we were waiting for permission from Audi Corporate, I did NOT ask how much it would cost if I wanted to pay for it myself. This still could be an option for those of you who cannot convince the service department to do the software update under warranty/for free.
Some MY 2021 vehicles (mine was delivered Mar 2021, probably built Dec 2020/Jan 2021) apparently already have the newer software version that supposedly prevents the generator from eating itself.

Hopefully this software update is truly a long-term fix, and this problem will not occur.

https://www.audiworld.com/forums/aud...012848/page22/

[pwdrskr]

Updated TSB: https://static.nhtsa.gov/odi/tsbs/20...22114-0001.pdf (oddly the RS 6 isn't listed but it definitely applies). From an Audiworld thread from an '21 RSQ8 owner (HDCL):

So here is a long update of my experience with Audi Service regarding the Electrical System Malfunction "Christmas Tree" error:

Back in April/May of 2022, I was idling in a parking lot and the S/S system kept cycling. It was a hot day, so the AC was running. After about 10 minutes, everything shut down and I got the various failure messages (Generator, 48V System, Active Differential, etc.) Shutting it down and restarting made the error go away. I did an OBD scan, and it showed a P065C00 - Generator Mechanical Performance - Intermittent fault.
The error never reoccurred, and I went on 2 long road trips in Nov/Dec (over 1,200 miles round trip) with no issues
I received the MMI backup camera recall notice and scheduled an appointment for Jan 2 at the Audi dealership. I informed them of the prior Generator error and code. They were aware of the TSB and have 5 vehicles awaiting a new generator that have completely failed. They agreed that at a minimum, the software update per TSB would probably be required.
On Jan 3, the service coordinator contacted me to get a screenshot of the OBD error code. Their scan revealed no error codes related to the generator or 48V system. There was one for the Active Differential. Audi Corporate was not giving them permission to just update the software with no error code, so they were trying to make a case for me. Due to people just coming back from the Holidays, there was some delay
Today (Jan 4), they informed me that they got the go ahead to flash the software, but when they tried to do it, the software version on the vehicle was already the version that the TSB was instructing to update to - hence no update done or required per Audi. At this point, there is nothing more that can be done from a preventative perspective. I am scheduled to go pick up the vehicle this afternoon. There will be a printout of the current software version installed (that matches the TSB) that I can try to upload here.


So, in summary, here are my key takeaways:

Audi does not seem keen to just flash the software as a preventative measure if there are no codes related to this error that they can use to justify the update
Your Service Coordinator is going to be the key in how this is handled for each of us individually. While we were waiting for permission from Audi Corporate, I did NOT ask how much it would cost if I wanted to pay for it myself. This still could be an option for those of you who cannot convince the service department to do the software update under warranty/for free.
Some MY 2021 vehicles (mine was delivered Mar 2021, probably built Dec 2020/Jan 2021) apparently already have the newer software version that supposedly prevents the generator from eating itself.

Hopefully this software update is truly a long-term fix, and this problem will not occur.

https://www.audiworld.com/forums/aud...012848/page22/

Thank you. Guess I'll have to wait...and hope. I'm fairly certain I have the most recent software, or at least most recent other than the 24ii update anyway. So far I've had no problems I know of related to this issue...fingers crossed.

BTW, FWIW, I was told by a swervice rep recently that Audi should have a fix for the MMI memory issues, Favorites not sticking, black screens, etc., is supposed to be available soon. Not holding my breath...

[pwdrskr]

Updated TSB: https://static.nhtsa.gov/odi/tsbs/20...22114-0001.pdf (oddly the RS 6 isn't listed but it definitely applies). From an Audiworld thread from an '21 RSQ8 owner (HDCL):

So here is a long update of my experience with Audi Service regarding the Electrical System Malfunction "Christmas Tree" error:

Back in April/May of 2022, I was idling in a parking lot and the S/S system kept cycling. It was a hot day, so the AC was running. After about 10 minutes, everything shut down and I got the various failure messages (Generator, 48V System, Active Differential, etc.) Shutting it down and restarting made the error go away. I did an OBD scan, and it showed a P065C00 - Generator Mechanical Performance - Intermittent fault.
The error never reoccurred, and I went on 2 long road trips in Nov/Dec (over 1,200 miles round trip) with no issues
I received the MMI backup camera recall notice and scheduled an appointment for Jan 2 at the Audi dealership. I informed them of the prior Generator error and code. They were aware of the TSB and have 5 vehicles awaiting a new generator that have completely failed. They agreed that at a minimum, the software update per TSB would probably be required.
On Jan 3, the service coordinator contacted me to get a screenshot of the OBD error code. Their scan revealed no error codes related to the generator or 48V system. There was one for the Active Differential. Audi Corporate was not giving them permission to just update the software with no error code, so they were trying to make a case for me. Due to people just coming back from the Holidays, there was some delay
Today (Jan 4), they informed me that they got the go ahead to flash the software, but when they tried to do it, the software version on the vehicle was already the version that the TSB was instructing to update to - hence no update done or required per Audi. At this point, there is nothing more that can be done from a preventative perspective. I am scheduled to go pick up the vehicle this afternoon. There will be a printout of the current software version installed (that matches the TSB) that I can try to upload here.


So, in summary, here are my key takeaways:

Audi does not seem keen to just flash the software as a preventative measure if there are no codes related to this error that they can use to justify the update
Your Service Coordinator is going to be the key in how this is handled for each of us individually. While we were waiting for permission from Audi Corporate, I did NOT ask how much it would cost if I wanted to pay for it myself. This still could be an option for those of you who cannot convince the service department to do the software update under warranty/for free.
Some MY 2021 vehicles (mine was delivered Mar 2021, probably built Dec 2020/Jan 2021) apparently already have the newer software version that supposedly prevents the generator from eating itself.

Hopefully this software update is truly a long-term fix, and this problem will not occur.

https://www.audiworld.com/forums/aud...012848/page22/

Thank you. Guess I'll have to wait...and hope. I'm fairly certain I have the most recent software, or at least most recent other than the 24ii update anyway. So far I've had no problems I know of related to this issue...fingers crossed.

BTW, FWIW, I was told by a swervice rep recently that Audi should have a fix for the MMI memory issues, Favorites not sticking, black screens, etc., is supposed to be available soon. Not holding my breath...

[DeputyDog95]

Just had mine replaced. There's evidence of coolant intrusion.

Cost out of warranty would have been $5,300. It was covered under warranty.

Tell us more about that. I'm not sure what you mean. When I think coolant intrusion, I'm thinking engine coolant in the oil.

[DeputyDog95]

My alternator died, but I have my car set up to never turn off except when at a complete stop.

How do you program it for a specific behavior?

All I know how how to do is either turn that feature on or off. I find the auto start stop feature way too aggressive as the car will turn off in the middle of 3 point turns and even while rolling at 6-7 mph as I'm approaching a stop light, whereas other cars I've owned you need to be stopped for a bit before it shut down. It's really annoying and dealer had no answer for me when I've complained about it other than disabling the feature every time I start the car.

[DeputyDog95]

My alternator went out last Fri. I was fortunate to be able to limp it to the dealer with error lights flashing before it finally quit. Supposedly they got the new alternator today and will have it back to me tomorrow. Which frankly I'm surprised about as I've heard other people waiting forever to get the alternator.

I am curious to know if they simply put in the same part as they pulled out or is there a newer revised version? I'll ask... I'm concerned that if you want to keep this car for any length of time, you'll have to factor in $5k every two years for an alternator if Audi hasn't revised it.

[FBAnder]

My alternator went out last Fri. I was fortunate to be able to limp it to the dealer with error lights flashing before it finally quit. Supposedly they got the new alternator today and will have it back to me tomorrow. Which frankly I'm surprised about as I've heard other people waiting forever to get the alternator.

I am curious to know if they simply put in the same part as they pulled out or is there a newer revised version? I'll ask... I'm concerned that if you want to keep this car for any length of time, you'll have to factor in $5k every two years for an alternator if Audi hasn't revised it.

Very likely same part. Probably got a software upgrade for the generator control module if it needed one.

[FBAnder]

How do you program it for a specific behavior?

All I know how how to do is either turn that feature on or off. I find the auto start stop feature way too aggressive as the car will turn off in the middle of 3 point turns and even while rolling at 6-7 mph as I'm approaching a stop light, whereas other cars I've owned you need to be stopped for a bit before it shut down. It's really annoying and dealer had no answer for me when I've complained about it other than disabling the feature every time I start the car.

You can drive in dynamic with the trans in sport mode all the time. I think just leaving the trans in sport mode will do it, too.

[Nsd991]

I find the auto start stop feature way too aggressive as the car will turn off in the middle of 3 point turns and even while rolling at 6-7 mph as I'm approaching a stop light, whereas other cars I've owned you need to be stopped for a bit before it shut down. It's really annoying and dealer had no answer for me when I've complained about it other than disabling the feature every time I start the car.

We just got a 2023 SQ8 and same thing. So abrupt even in a luxury SUV. Surprised the development engineers allow this to permeate through the Audi lineup. Drive a Mercedes or BMW and no where as jarring. I have to drive in S all the time which wastes more fuel than the auto stop/start could ever save.

[pwdrskr]

How do you program it for a specific behavior?

All I know how how to do is either turn that feature on or off. I find the auto start stop feature way too aggressive as the car will turn off in the middle of 3 point turns and even while rolling at 6-7 mph as I'm approaching a stop light, whereas other cars I've owned you need to be stopped for a bit before it shut down. It's really annoying and dealer had no answer for me when I've complained about it other than disabling the feature every time I start the car.

Can't speak for robwrongshoes, but I used this Auto Start/Stop memory module. It's plug and play and installs under the rear seat. It causes the Auto Start/Stop system to retain the last state it was in when the car was shut off. This way, if the Auto Start/Stop system was turned off at the time the car was shut off, it will be off again when the car is restarted. This was the first mod I made after getting the car. I HATE the "feature"! Anyway, it works beautifully and I highly recommend it. The seller is in Australia so it takes a little bit to arrive. They are very responsive if you need help even with the time differences. The current version I linked to is 100% plug and play and is quite easy to install.

There is also a coding tweak that will defeat the Auto/Start Stop using OBD Eleven or some other OBD coding tool such Ross-Tech VCDS. I think it causes the A/C to stay on at all times and that in turn causes the Auto/Start Stop system to stay off. I could be wrong on that....maybe someone else can weigh in on that bit.

[F10TT]

Tell us more about that. I'm not sure what you mean. When I think coolant intrusion, I'm thinking engine coolant in the oil.

The generators on our cars are liquid cooled. The seals are either faulty or the coolant is eating the seals, which in turn leaks coolant into the generator and fries the internals.

[The_Capt]

The generators on our cars are liquid cooled. The seals are either faulty or the coolant is eating the seals, which in turn leaks coolant into the generator and fries the internals.

So is that the technical reason for the failures and subsequent TSB?

Sounds like a poor design that is hopefully remedied in v2 of the alternator


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[FBAnder]

The generators on our cars are liquid cooled. The seals are either faulty or the coolant is eating the seals, which in turn leaks coolant into the generator and fries the internals.

Don't see how a software update fixes that. Aiyeeee

[MichaelScott]

My car bricked last night in traffic. Fuck that sucked. Service told me they have a fix, might be back by monday, but only because they have the fix for this platform and not the # of other vehicles on the lot (diff platform) they have no fix for


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[DeputyDog95]

My car bricked last night in traffic. Fuck that sucked. Service told me they have a fix, might be back by monday, but only because they have the fix for this platform and not the # of other vehicles on the lot (diff platform) they have no fix for


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A "fix"? As far as I know and if it's the same as the rest of us, you need a new alternator.


It took a week, with no loaner I might add (Grrrrrr), but I got my car back today after the alternator replacment.

"If" and it's a big one at this point, I keep this car, I'm 100% getting the extended warranty when my lease is up in 9 or so months.

[F10TT]

A "fix"? As far as I know and if it's the same as the rest of us, you need a new alternator.


It took a week, with no loaner I might add (Grrrrrr), but I got my car back today after the alternator replacment.

"If" and it's a big one at this point, I keep this car, I'm 100% getting the extended warranty when my lease is up in 9 or so months.

I've seen the order list for generators at my local dealer. One Q8 has been waiting since the first week of November and an RS car has been waiting since the day before Thanksgiving. I don't see how the dealers have a fix for this when it's either faulty construction or faulty seals that *seem to be* causing the issues.

[DeputyDog95]

I've seen the order list for generators at my local dealer. One Q8 has been waiting since the first week of November and an RS car has been waiting since the day before Thanksgiving. I don't see how the dealers have a fix for this when it's either faulty construction or faulty seals that *seem to be* causing the issues.

Agreed.

I wonder how my dealer was able to get the part so quickly???

I was fully expecting to wait weeks or maybe even months...

[OneFastBMW]

Agreed.

I wonder how my dealer was able to get the part so quickly???

I was fully expecting to wait weeks or maybe even months...

I wonder if those are cars in the dealer’s inventory, not customer cars. Maybe Audi is prioritizing parts to customer cars. There is a C8 RS7 at my local dealer that has been sitting on the showroom for nearly a year waiting on some part. Luckily Audi is compensating the dealer since they cannot sell the car.

[pwdrskr]

If the issue is a physical defect in design/parts, I'm wondering how Audi of America could legitimately deny warranty replacement on a modified car. Water intrusion, for example, isn't going to be dependent on ECU coding, is it? This is one I'd take Audi to court if it came to it. As I understand the law on this issue, it is incumbent upon the manufacturer to prove the modification caused the failure. Not trying to spark yet another debate about warranties, tuning, etc. Just trying to figure out the logic, if I can..

[OneFastBMW]

If the issue is a physical defect in design/parts, I'm wondering how Audi of America could legitimately deny warranty replacement on a modified car. Water intrusion, for example, isn't going to be dependent on ECU coding, is it? This is one I'd take Audi to court if it came to it. As I understand the law on this issue, it is incumbent upon the manufacturer to prove the modification caused the failure. Not trying to spark yet another debate about warranties, tuning, etc. Just trying to figure out the logic, if I can..

Has anyone had this repair denied because of a tune?

Here is a thread where someone with an APR Tune originally had it denied then subsequently Audi replaced it. I could see them making a case for not replacing it since the 48v starter/generator does actually “propel” the vehicle and could be considered part of the drivetrain. It provides up to 6hp continuously and 8hp for up to 5 seconds. If the ECU tune were to make the motor supplement power more than Audi designed it could harm the unit. However, water intrusion would be hard to claim anything with a tune caused a seal/gasket to leak.

Contact Needed for Audi Corporate

[DeputyDog95]

So, I'm getting whiffs of coolant after having the alternator replaced. Since the alternator is liquid cooled, which was news to me, I'm assuming this is not a coincidence.

I texted my service advisor and he said it might just be residual coolant from the install, but said I should check the coolant level while the car is cold to be sure.

So, I popped the hood and I don't see the expansion tank. I googled it, came up empty.

I'm sure it's the manual somewhere, but can someone tell me how to examine the expansion tank level? I'm sure it's probably under some plastic cover somewhere under the hood.

Thank you.

[Jimminez]

Has anyone had this repair denied because of a tune?

Yes, I am aware of individuals who did not have repair covered under warranty due to them being TD1 flagged.

[F10TT]

So, I'm getting whiffs of coolant after having the alternator replaced. Since the alternator is liquid cooled, which was news to me, I'm assuming this is not a coincidence.

I texted my service advisor and he said it might just be residual coolant from the install, but said I should check the coolant level while the car is cold to be sure.

So, I popped the hood and I don't see the expansion tank. I googled it, came up empty.

I'm sure it's the manual somewhere, but can someone tell me how to examine the expansion tank level? I'm sure it's probably under some plastic cover somewhere under the hood.

Thank you.

So what's leading me more to water on this one is the week PRIOR to my generator going, my coolant system lost every ounce of coolant. Literally bone dry. A pressure test came back fine so I took the car home and like clockwork after the car sat for three days, I got the malfunctions. If dealerships start cracking open more of these generators I'm going to say a majority are failing because of coolant intrusion.

The panel to access the coolant tank is on the passenger side under the plastic panel. See the circle below.

Yes, I am aware of individuals who did not have repair covered under warranty due to them being TD1 flagged.

Echoing this. It's happened here in the DC Metro area but I was able to have somebody use a template of a letter I had to get the dealership through Audi to cover it.

[DeputyDog95]

Thanks! I was able to find it finally. Audi does a good job of hiding all this stuff :)

I wish I had known about the coolant, I would have liked to have checked the coolant level when mine was failing, just cause. I never got any temp warnings or low coolant warnings, but it would have been interesting regardless.

Right now, my coolant level seems just fine and the dealer thinks I'm probably just smelling residual coolant from the install.

Apparently Audi quotes this as a 10 hour job, and it took my dealer 15. The way he described it, sounded like they had to remove a lot of the front end to get at the fittings and that it was a bear of a job. Seems absurdly complicated for what should be a simple alternator repair...

[FBAnder]

Thanks! I was able to find it finally. Audi does a good job of hiding all this stuff :)

I wish I had known about the coolant, I would have liked to have checked the coolant level when mine was failing, just cause. I never got any temp warnings or low coolant warnings, but it would have been interesting regardless.

Right now, my coolant level seems just fine and the dealer thinks I'm probably just smelling residual coolant from the install.

Apparently Audi quotes this as a 10 hour job, and it took my dealer 15. The way he described it, sounded like they had to remove a lot of the front end to get at the fittings and that it was a bear of a job. Seems absurdly complicated for what should be a simple alternator repair...

Absurdly complicated and German engineering go hand in hand. Ever need to work on a B5 S4??? Haha. Drop subframe and move radiator into service position was fairly standard.

Looks like I should be paying more attention to my coolant level.

[Corgiman30]

Absurdly complicated and German engineering go hand in hand. Ever need to work on a B5 S4??? Haha. Drop subframe and move radiator into service position was fairly standard.

Looks like I should be paying more attention to my coolant level.

I had a neighbor who was an engineer and he described engineering as if you have a problem:
1 The British solution is most practical
2 The American solution is cheapest
3 The Japanese will look at what everyone else has done and come up with a hybrid
4 The Germans will get an idea and make it work no matter how costly or complex it becomes.