Disassembly
Remove the generator.
Remove the three through bolts and disconnect the support flange on the drive side from the stator.
Carefully clamping the rotor in a vise, unscrew the center pulley bolt. Remove the pulley with the fan impeller and spacer.
Remove the rectifier from the back cover of the generator.
Early generator models
- Unsolder the three wires on the stator winding coming from the rectifier while holding the connection terminal with pliers.
- To replace carbon brushes when wear has reached wear limits (length about 5 mm or less), unsolder the lead wires.
Later generator models
If the brush (1) worn to the center of the mark (3 mm from the middle of the brush holder), replace the brush holder assembly.
- Check free rotation of both rotor bearings or replace them. A puller and press tool is required to replace the rear bearing.
Assembly
In early generator models:
- Insert the brushes and springs into the brush holder and solder the leads. Trim the long ends.
- To prevent the solder from penetrating into the brush leads when soldering, hold the brush leads with pliers.
Check the ease of movement of the new brushes in the brush holder.
Place the rear part on the rotor and close. Slide on the front support flange with spacer sleeve and slide on the link sleeve.
Install the fan impeller with pulley and circlip by tightening the nut to 60 Nm.
Insert into the generator housing, bending the ends of the rectifier connection wires so that they do not touch the rotor. Hold the brushes in a compressed position when assembling.
Secure the housing with three through bolts.
Check the ease of rotation of the generator by hand.
Install the generator.
Connect ground wire to battery.
If available, set the clock to the time and enter the security code into the radio.
Generator elements of early car models
1 - belt pulley;
2, 4 - stuffing box;
3 - support flange;
5 - bearing from the drive side;
6 - bearing retaining plate;
7 - stator;
8 - rotor;
9 - rotor bearing;
10 - brush holder / voltage regulator;
11 - connection terminals;
12 - carbon brush;
13 - spring;
14 - rectifier;
15 - back cover.
Generator elements of late car models
1 - pulley;
2 - stuffing box;
3 - flange;
4 - bearing;
5 - bearing holder;
6 - stator;
7 - bearing;
8 - bearing cover;
9 - stator with rectifier unit;
10 - brush holder;
11 - back cover of the generator.
The carbon brushes of the generator wear out on average over 120 thousand km. To replace it, the alternator must be disassembled.