Generator repair (VW Golf 1)

The Golf, Jetta, and Scirocco models can be equipped with one of two types of alternators: Bosch or Motorola (drawing D:7, D:8, D:9). The following procedure for replacing the brushes and voltage regulator applies to both types of generators, as their design is basically the same.

Replacing brushes and voltage regulator

The brushes are mounted in a brush holder attached to the voltage regulator. Remove the alternator from the vehicle as described previously. Remove the regulator mounting screws (shown by arrows in the figure D:4, D:5) and remove the regulator and brush assembly. Measure the free length of the brushes as follows:

1. Inspect the brushes for wear. In a free position, measure the length of the part of the brushes protruding from the brush holder (A, figure D:10 and D:11). If the free length of the brushes approaches that specified in section "Technical data" or less, replace the brushes.

2. Unsolder the brush conductors from the holder and remove the old brushes from their sockets. Carefully solder the new brush conductors (drawing D:11, D:12).

3. Install the new brushes into the sockets and make sure that the brushes move freely.

When installing a new voltage regulator, the brushes should also be replaced. The regulator is supplied with a brush holder to which new brushes should be soldered as described earlier. The connections on the Motorola alternator are slightly different from those described (drawing D:13, D:14).

Install the voltage regulator assembly with brush holder to the rear of the alternator and secure with bolts. Install the alternator to the vehicle and check the output current under load as described previously.