The voltage regulator and the generator brushes are made as a single unit. In Bosch generators, this unit can be removed and its components serviced separately (see section Replacing the voltage regulator).
On all models, the alternator is mounted on the left side of the engine and is driven by a V-belt from the engine pulley. In these systems, the two main requirements are belt tension and battery maintenance. Checking engine belt tension and battery maintenance are described in Chapter Routine car maintenance.
When the ignition key is turned to the "START" position, the charge/ignition indicator lamp should light up, then go out immediately after the engine starts. If the lamp remains on, the charging system is faulty (see section Checking the charging system). Some vehicles are also equipped with a voltmeter. If the voltmeter shows abnormally high or low voltage, check the charging system (see section Checking the charging system).
On models up to 1986, if the charge control lamp/ignition switch burns out, the generator stops charging. After 1987, a resistor is installed in parallel with the control lamp to ensure that current passes around the lamp in the event of a break in the circuit (lamp burnout).
Precautionary measures
Be very careful when making electrical connections to the generator and note the following:
- When connecting the battery wires to the generator, make sure the polarity is correct.
- Before performing any repairs to any part of the vehicle using arc welding, disconnect the wires from the battery and generator.
If your vehicle's radio is equipped with an anti-theft system, make sure you know the correct activation code before disconnecting the battery. Refer to Section 1 for information before disconnecting the wire Anti-theft audio system and instrument cluster language.
If a message in another language appears on the instrument cluster display after connecting the battery, refer to Section 1 for the language setting procedure Anti-theft audio system and instrument cluster language.
- Never start the engine with the battery charger connected. Always disconnect both cables before using the battery charger.
- Never disconnect any wires from the battery or generator while the engine is running.
- The generator is driven by the engine drive belt. Serious injuries can occur if hands, hair or clothing get caught in the belt while the engine is running.
- Since the generator is directly connected to the battery, take care not to short the main terminal to ground.
- Before cleaning the engine with hot steam, wrap the generator in a plastic bag with rubber bands.