Replace/check brushes for alternator/voltage regulator

• Remove the serpentine belt - 1 - and the alternator - 2 -.

• Unscrew the alternator protective cap - 5 - with 3 bolts - 6 -.

• Unscrew the voltage regulator - 3 - from the rear of the alternator (2 screws - 4 -) and carefully pull it out.

• Replace the brushes - 2 - if the length is 5 mm or less. To do so, unsolder the connecting lead.

• Check the slip rings for wear; if necessary, lightly turn them down and polish.

• Clean the contact surface and check the preload of the contact spring; replace if necessary.

• Insert the carbon brushes - a - and springs - b - into the brush holder - c - and solder the connections.

• To prevent solder from wicking up into the lead when soldering the new brushes, grip the brush lead with flat-nose pliers. Caution: Solder wicking up the lead would make it stiff and render the carbon brush unusable.

• The insulating sleeve over the lead must be clamped next to the solder joint using the existing eyelet.

• After installation, check that the new carbon brushes move freely in the brush holders.

• First fasten the voltage regulator loosely by hand with one screw, then carefully press it into its final installed position and tighten the screw.

• Screw the protective cap onto the rear of the alternator.

• Install the alternator.

• Pry the plastic cover off the rear of the alternator with a screwdriver and remove it.

The illustration shows the brushes - 1 - with the diode plate removed.