Delco-Remy type (except "compact")
Removal
1. Remove the generator as described in Chapter 9.
2. Draw a line to align the casings.
3. Unscrew the three tie bolts, remove the drive side casing and the rotor from the other half of the casing and the stator (see illustration).
4. Check the condition of the generator rings, if necessary, clean them with a cloth or very fine sandpaper (see illustration).
5. Unscrew and remove the three nuts and washers securing the stator wiring to the rectifier, remove the stator assembly (see illustration).
6. Loosen the screw and lift up the diode assembly.
7. Remove the two screws securing the brush holder and voltage regulator to the slip ring housing and remove the brush holder assembly. Note the location of the insulating washers under the screw head.
8. Check that the brushes move freely in the guides and that their length is within the limits given in Specifications. If you are in doubt about the condition of the brushes, it is better to replace them.
9. To install new brushes, unsolder the contacts of the old brushes from the brush holder and solder the new ones in their place.
10. Check that the new brushes move freely in the guides.
Installation
11. Before installing the brush holder assembly, secure the brushes in a fixed position using a piece of wire or a drill.
12. Install the brush holder assembly so that the wire or drill protrudes through the groove in the housing with the sliding ring, tighten the mounting screws.
13. Install the diode assembly and stator assembly into the housing, tighten the screws and nuts.
14. Assemble the housings with the rotor together, aligning the previously made marks. Insert and tighten the three tie bolts.
15. Remove the wire or drill from the groove in the housing with the slip ring so that the brushes rest on the generator rotor rings (see illustration).
16. Install the generator as described in Chapter 9.
Generator type Bosch
Removal
17. Disconnect the main air duct from the air cleaner, air block or throttle body, depending on the model, and remove it for better access.
18. Disconnect the battery wiring.
19. If required for better accessibility, the generator can be removed as described in Chapter 9.
20. Unscrew the two mounting screws and remove the brush holder/voltage regulator assembly (see illustrations).
21. Check that the brushes move freely in the guides and that the length of the brushes is within the limits given in Specifications (see illustration).
If you are in doubt about the condition of the brushes, it is best to replace them as follows.
22. Unsolder the brush wire from the brush holder. Remove the brush. Do the same with the remaining brush.
Installation
23. Please note that whenever new brushes are installed, new springs must also be installed.
24. Install new springs in the brush holder, insert new brushes, and check that they move freely in the guides. If they stick, file them down slightly with a fine file or sandpaper.
25. Solder the ends of the brush wires to the brush holder, being careful not to let any solder get on the twisted wire.
26. Check the condition of the generator rings, if necessary clean them with a cloth or very fine sandpaper (see illustration).
27. Install the voltage regulator brush holder assembly and tighten the mounting screws.
28. Where necessary, install the generator as described in Chapter 9.
29. Reconnect the battery wiring.
30. Install the main air duct.
Delco-Remy "compact"
Removal
31. Remove the generator as described in Chapter 9.
32. Remove the plastic cover from the back of the generator.
33. Remove the two bolts securing the brush holder to the rear of the generator, one bolt also secures the interference suppression capacitor.
34. Remove the noise suppression capacitor, then pull out the brush holder, noting the position of the flat connector on the side.
35. Check that the brushes move freely in the holders and that the brush length is within the limits given in the Specifications. If you are in doubt about the condition of the brushes, it is better to replace them.
36. Check the condition of the generator rings, clean them with a cloth or fine sandpaper.
Installation
37. The brush is installed in the reverse order.
Visitor comments