Alternators can be of different designs depending on the model of the car. Removal of brushes for all engines of release from 5/87 and for diesel engines of release from 5/83 is carried out without removing the generator.
Removing
Disconnect ground cable (-) from the battery.
Attention: As a result, the records in the memory of the on-board computer are erased. In particular, a fault record and a radio code. Before disconnecting the battery, read the contents of the section «Removing and installing the battery».
Gasoline engines up to 4/87 of release
Remove generator.
Unscrew the three screws and remove the covers from the drive side. Be careful not to damage the stator winding with a screwdriver (pic. G-5416).
Lightly clamp the alternator rotor in a vise and release the central pulley mounting bolt. Remove the pulley together with the wing and spacer sleeve.
Remove four nuts, two terminal insulators and wire tie. Then remove the rear rotor cover.
Remove the insulators from the stud supports.
Unsolder the stator winding wire from the rectifier board. In this case, it is necessary to clamp the wire with pliers to protect the rectifier from overheating.
Replace brushes if protrusion length is 5.5 mm or less. To do this, unsolder the connecting stranded wire.
Check the slip rings on the rotor for wear. Clean rings if necessary.
Check the rotor bearings for ease of movement. Replace if necessary. The rear bearing is pressed in. You need to remove it with a puller.
Installation
Insert the brush and spring into the brush holder and solder. The brush should protrude 12.5 mm.
When soldering, pinch the connecting stranded wire of the brush with pliers to prevent solder from getting on it.
Attention: When solder gets into the wire, it becomes hard, which leads to its failure.
After installation, check the ease of movement of the brushes in the brush holder.
Solder the wire connecting the stator to the rectifier board, making sure that the rectifier does not overheat.
Install the rear shroud onto the alternator rotor.
Install the cover on the drive side.
Install impeller with pulley and circlip.
Tighten the fixing nut to 60 Nm.
Assemble the generator housing. Bend back the rectifier contact first so that it does not touch the rotor. At the same time, keep the brushes pushed in with a wire. There is a hole on the rear bearing cover for this.
Fasten the case with three special screws.
Remove the wire holding the brushes and close the hole with sealant.
Check the ease of rotation of the rotor.
Install the generator.
Removing the generator from the engine from 5/87 of release
Loosen three nuts and remove the back cover.
Remove 5 screws and remove brush holder and regulator.
Replace the brushes if their protrusion is 4.5 mm or less.
Installation
Insert the brush and spring and solder the connection. The brush should extend 10.5 mm.
Make sure that the solder does not get on the stranded wire connecting the brush.
Caution: Solder intrusion hardens the wire, preventing the brush from working properly.
Check the ease of movement of the brush in the brush holder.
Close the brush holder cover (3 screws). When doing this, make sure that the gap between the holder and the plug is at least 1 mm.
Install and screw the back cover of the generator.
Removing the diesel generator
Attention: Diesel generators are partly installed in the same way as petrol engines since 5/87. Check it out in the following pictures.
Disconnect the wire and remove the cover.
Version without electronic controller: Detach insulating seal and connecting cable. Remove the nut and remove the brush holder (pic. G-5427).
Version with electronic controller: Loosen the screw on the brush holder and disconnect the blue wire. Take out the regulator and then disconnect the white wire.
Unscrew the two screws and remove the electronic unit from the brush holder.
Replace brushes if they protrude 5.5 mm or less.
Installation
Insert the brushes and springs into the brush holder and solder the brushes. The brush should extend 20 mm.
Check the ease of movement of the brushes in the brush holder.
Install the assembled generator in place.
Connect ground cable (-) with rechargeable battery.
Set the time on the clock, if any. Enter the code into the radio.