Table of contents: Removal ↓ Installation ↓
Removing the brushes is possible without removing the generator, however, to do this it is necessary to remove the upper part of the intake manifold.
Removal
1. Disconnect the negative (–) battery cable with the ignition off.
Warning: This will erase information from electronic memory units, such as the radio code. Without the code, the radio can only be switched on by the manufacturer or an AUDI service station. Therefore, please read the materials in the subsection Entering the radio code.
2. Remove the V-belt, referring to the subsection Removal and installation the V-belt.
3. Remove the generator.
4. VALEO Generator: Remove the generator protective cover.
5. Disconnect the voltage regulator from the back of the generator and carefully remove it.
6. Replace the brushes if their length is 5 mm or less. To do this, unsolder the wire.
7. Check the contact rings for wear, and if necessary, sharpen and polish them.
8. Clean the contact surfaces and check the tension of the contact springs, replace if necessary.
Installation
9. Insert the brushes (A) and springs (B) into the brush holder (C) and solder the cables.
10. To prevent solder from getting on the cables when soldering new brushes, hold the brush cables with pliers.
Warning: Solder will cause the cable to become too stiff and the brush will not work.
11. The insulating hose above the cable should be clamped near the soldering point together with the existing eyelet.
12. After installation, check the new brushes for ease of movement in the brush holders.
13. Manually tighten the voltage regulator with one bolt, then gently push it into the final position and tighten it.
14. Secure the generator protective cover.
15. Reinstall the generator.
16. Install the V-belt, referring to the subsection Removal and installation a ribbed V-belt.
17. Connect the negative (–) cable to the battery.
Warning: Activate the automatic safety of the electric windows, and also set the time and enter the code of the radio receiver, while referring to the subsection Removal and installation the battery and subsection Entering the radio code.