Disassembly and assembly of the generator (Audi 100 C3)

Disassembly and assembly of the generator is not difficult (refer to the detail view below, which shows the sequence of removal and installation of parts). When inspecting parts, check:

• the condition of the brushes, their degree of wear, the fit of the brushes to the rings and the pressing force of the springs;
• appearance of slip rings. The slip rings can only be cleaned with a clean rag soaked in petrol or trichlorethylene. Clean slip rings only with fine-grained abrasive paper. It is forbidden to use emery cloth for this purpose;
• bearing condition. They do not require maintenance. because they contain a long-lasting lubricant;
• appearance of the rotor and stator. Make sure that their windings do not have breaks or burn marks.

Note. In no case should the electrical characteristics of the generator be tested with a circuit with a voltage of more than 40 V. Otherwise, some elements of the generator may fail. Check the diodes only in a circuit with a DC voltage of not more than 12 V.

Rectifier diodes are sensitive to high temperatures, so when replacing them, solder as soon as possible using tongs with sponges. For this purpose, it is recommended to use an electric soldering iron with a power of not more than 300 W, since if the insulation of the electric soldering iron is broken, the diodes can be disabled.

To clean the generator parts, use white spirit or trichlorethylene; immediately after cleaning, dry the parts, especially the windings, with compressed air.