1 - Belt pulley
2 - Oil seal
3 - Support flange
4 - Oil seal
5 - Drive side bearing
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
The carbon brushes of the generator wear out rather slowly; on average, they wear out over 120,000 km. It is recommended to replace the brushes in advance, for which the generator should be disassembled.
Removing
Remove generator.
Loosen 3 through bolts and separate the support flange from the drive side from the stator, while not resting against the winding inside the generator.
Carefully clamp the rotor in a vise and loosen the pulley center bolt. Remove the pulley with the fan impeller and spacer.
Disconnect the rectifier from the back cover of the generator.
Unsolder 3 wires on the stator winding coming from the rectifier, while holding the connection terminal with pliers to remove heat from the rectifier.
Replace carbon brushes if wear reaches wear mark (length about 5mm or less). To do this, unsolder the lead wires.
Check both rotor bearings for free rotation and replace if necessary. The rear bearing is pressed in and requires a puller and press tool to replace it.
Installation
Insert brushes and springs into the brush holder and solder the leads. Trim protruding ends.
Since during soldering the solder should not penetrate into the wires of the brush supply, hold the brush supply with pliers.
Attention: Ingress of solder makes the brush leads rigid, after which the brushes cannot be used.
After installing new brushes, check the ease of their movement in the brush holder.
Solder the wires from the stator to the rectifier, preventing the rectifier from overheating.
Push the back of the housing onto the rotor and close. Put on the front support flange with spacer sleeve and put on the connecting sleeve.
Fit the fan impeller with pulley and spring ring and tighten 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. In addition, when assembling, hold the brushes in a compressed position with a suitable wire.
Fasten the body with 3 through-bolts.
Make sure the alternator turns easily by hand.
Install generator.
Connect ground cable to battery.
If available, set the time on the clock and enter the security code into the radio.