Replacing the brushes of the generator and Bosch voltage regulator

Bosch generator

The voltage regulator and alternator brushes can be replaced without removing the alternator from the engine.

1. Remove ground wire from battery.

2. Unscrew the 3 screws and remove the heat shield.

3. Unscrew the 2 screws securing the voltage regulator and, being careful, remove the regulator.



4. Check the length of the graphite brushes, which must be at least 5 mm.



5. To replace the carbon brushes, it is necessary to unsolder the current leads, remove the worn brushes and springs, install new brushes with springs in the regulator socket and solder the current lead so that the length of the brushes is 10 mm. When soldering, do not allow flux and solder to get on the current lead, except for the place of soldering (1 - brushes, 2 - brush pressure springs, 3 - brush holder).

6. Check the ease of movement of the brushes in the holder.