Replacing the generator brushes and voltage regulator (VW Golf 4)

The voltage regulator and generator brushes can be replaced without removing the generator from the engine, but it is necessary to remove the upper part of the intake manifold.

Removal

1. Turn off the ignition and remove the ground cable from the battery.

2. Loosen the tension and remove the alternator drive poly V-belt.

3. Remove the generator.

4. Unscrew the screws and remove the protective cover from the rear of the generator.



5. Unscrew the two screws and carefully remove the voltage regulator along with the brushes from the generator.

6. Measure the length of the graphite brushes, which should be at least 5 mm.

Replacement

To replace the carbon brushes, unsolder the current leads, remove the worn brushes (A) and springs (B), install new brushes with springs in the regulator socket and solder the current lead so that the length of the brushes is 10.0 mm. When soldering, do not allow flux and solder to get on the current lead, except for the soldering point. Check the ease of movement of the brushes in the holder (C).

Installation

1. Carefully install the voltage regulator with brushes and secure it with screws.

2. Install the generator protective cover and secure it with screws.

3. Install the generator.

4. Install the alternator drive poly V-belt and adjust its tension.

5. Connect the ground wire to the battery.