Generator brushes — checking and replacement (Audi 80 B3)

1. Access to the rear of the alternator on 4-cylinder models is easy, the brushes and voltage regulator can be removed without removing the alternator from the engine. However, on 5-cylinder models it is better to remove the alternator first.

2. Disconnect the negative battery cable (following Chapter 3, paragraph 2).

3. Loosen and remove the screws securing the brush holder and voltage regulator to the rear of the generator (photo).



4. Remove the brush holder and voltage regulator by turning it slightly (photo).



5. Measure the length of the brushes protruding from the holder (photo). If the length of any brush is 5.0 mm or less, the unit must be replaced.



6. Clean the rings inside the generator with a cloth soaked in fuel by turning the pulley (photo). If they are very dirty, clean them with fine sandpaper.





7. Check that the brushes move freely in the holder, then insert the brush holder and voltage regulator into place on the generator.

8. Insert and tighten the screws.

9. Connect the negative battery cables.