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.
Disconnect the negative battery cable.
Bosch generator
1. Remove the voltage regulator from the back of the generator (see Section Replacing the voltage regulator).
2. Measure the length of the brushes. They must not be shorter than 6 mm. If any of them are worn to this limit, replace the entire set.
3. Also check for wear on the manifold ring (Look illustration).
4. The brushes are either fixed with screws or soldered. If you are not experienced with soldering, it may be best to have the brushes installed by an electrician.
Be careful not to heat the soldering area for more than 5 seconds. Use a heat sink if necessary to prevent overheating. This can be done with narrow pliers, which should be wrapped around the part near the soldering point.
5. For screw mounting, hold the assembly in place and install the screws. Tighten the screws little by little evenly so that the holder does not warp.
6. Install the voltage regulator assembly to the generator.
7. Connect the negative battery cable.
Motorola Generator
1. Remove the generator.
2. The brushes are installed under the voltage regulator at the back of the generator (Look illustration).
3. Remove the mounting screws and insulating washers and separate the voltage regulator and brush holder from the housing on the collector side.
4. Measure the length of the brushes (see illustration above). If any of the brushes are shorter than 6mm, replace the entire set.
5. Check that the brushes move without binding in the brush holder.
6. Install the brush holder/voltage regulator. Tighten the screws firmly. Make sure the brushes are not shorted to ground.
7. Installation is reverse to removal.