Attention: Brushes can be replaced separately only on the BOSCH generator. For generators of other manufacturers, it is necessary to replace the assembly of the relay-regulator.
Withdrawal
Disconnect ground wire (-) battery.
Attention: This erases the contents of electronic memory devices such as the engine fault code memory or the radio memory. Therefore, before disconnecting the battery, be sure to read the instructions in chapter "Removing and installing the battery".
Remove poly V-belt -1-, see p. 29.
Remove alternator -2-.
Release screws -6- of protective cover -5- of alternator.
Unscrew the 2 screws -4- securing the relay-regulator -3- from the reverse side of the generator and carefully remove it.
If the length of the brushes is less than 5 mm, replace the brushes. To do this, unsolder the cores of the connecting wires.
Check the slip rings for wear, finely grind and polish the rings if necessary.
Clean the contact surfaces and check the preload of the contact springs, replace the springs if necessary.
Installation
Insert the brushes -A- and springs -B- into the brush holder -C- and solder the connecting wires.
So that when soldering a new brush, the solder does not rise along the core to be soldered, it must be covered with tweezers.
Attention: When solder spreads along the core, it becomes hard, as a result of which the brush becomes unusable.
The insulating sleeve of the core must be fixed next to the soldering point with the existing lug.
After installing new brushes, check the ease of their movement in the brush holder.
Insert the relay-regulator and fasten it first with one screw, then carefully press it into the final mounting position and tighten both screws.
Screw on the protective cover of the generator.
Install generator.
Install poly V-belt see p. 29.
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