Attention: The contact brushes can only be replaced separately with a Bosch generator. For other generators, the voltage regulator assembly needs to be replaced.
Removing
Disconnect the negative cable from the battery.
Attention: This will erase the data from the electronic memory units.
Remove poly V-belt (1).
Remove alternator (2).
Unscrew the bolts (6) generator cover (5) and remove the cover.
Unscrew the screws (4) voltage regulator mounts (3) from the back of the alternator and carefully pull out the regulator.
Replace the carbon brushes when their length is less than 5 mm by unsoldering the connecting wires.
Check slip rings for wear, sharpen and polish if necessary.
Clean the contact surfaces and check the force of the contact springs, replacing them if necessary.
Installation
Insert brushes (A) and springs (IN) into the brush holder (WITH) and solder the wires.
To prevent solder from getting into the wires when soldering new brushes, press the wires of the brushes with pliers when soldering.
Attention: Due to the solder getting into the wires, the wires can become stiff and the brushes will quickly fail.
The insulating tube on the wire must be pinched near the soldering point.
After installation, check the ease of movement of the new carbon brushes in the brush holder.
First fasten the voltage regulator with one screw, and then carefully press into the final position and secure completely.
Install the generator cover.
Install generator.
Install poly V-belt.