Note: On some models it may be desirable to remove the alternator as described in Chapter 7 due to restricted access.
1. Disconnect the negative battery cable.
2. Remove the two screws and remove the brush holder and voltage regulator from the back of the generator (photo).
3. Measure the length of the brushes (photo). If they are worn below the minimum length, they must be replaced as follows.
4. Clamp the brush wires with pliers and unsolder from the brush holder. Remove two brushes.
5. Insert new brushes and check that they move freely in their guides. If they stick, lightly polish with a very fine file.
6. Solder the brush wire to the ends of the brush holder, being careful not to get any solder on the twisted wire.
7. Whenever new brushes are installed, new springs must also be installed.
8. Clean the alternator slip rings with a cloth dampened with gasoline.
9. Installation is carried out in the reverse order.
Type of Bosch generator (chapter 8)
1 Nut
2 Pulley
3 Fan
4 Drive side cover
5 Bearing
6 Mounting plate
7 Rotor
8 Stator
9 Brush guard
10 Brush holder and voltage regulator
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