Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Starting/Charging Systems (H4SO): Generator: Inspection: Brush
- Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush.
Brush length:
- 2.5 L model
Standard (1)
18.5 mm (0.728 in)
Limit (2)
5.0 mm (0.197 in)
- 3.6 L model
Standard (1)
22.5 mm (0.886 in)
Limit (2)
5.0 mm (0.197 in)
- 2.5 L model
- Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is 2.648 N (270 g, 9.52 oz) or less, replace the brush spring with a new part. 4.609 - 5.786 N (470 - 590 g, 16.58 - 20.810 oz) pressure is required on the new spring.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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