The voltage regulator and the generator brushes are made in the form of a single unit. On Bosch generators, this assembly 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 rotated by a V-belt from the engine pulley. In these systems, the two main requirements are belt tension and battery maintenance. Check of a tension of a belt of the engine and service of the battery are described in the Chapter Car maintenance.
When the ignition key is turned to position «START» (launch) the charge control/ignition control lamp should light up, then go out immediately after starting the engine. If the lamp continues to burn, then the charge system has a malfunction (see Section Checking the charge 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 charge system).
On models up to 1986, when the charge control / ignition lamp burns out, the generator stops charging. After 1987, a resistor was installed in parallel with the control lamp to allow current to bypass the lamp in the event of an open circuit (lamp burnout).
Precautionary measures
Be very careful when making electrical connections to the generator and pay attention to the following:
- Make sure the polarity is correct when connecting the battery wires to the generator.
- Before repairing any part of the car 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. Before disconnecting the wire, refer to Section Anti-theft audio system and instrument panel language.
If a message in a different language appears on the instrument panel display after connecting the battery, refer to Section Anti-theft audio system and instrument panel language.
- Never start the engine with the charger connected to the battery. Always disconnect both wires before using the battery charger.
- Never disconnect the wires from the battery or alternator while the engine is running.
- The generator is rotated by the engine drive belt. Serious injury may result if hands, hair, or clothing are caught under 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.
- Wrap the generator in a plastic bag with rubber bands before cleaning the engine with hot steam.