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PART
13-2-BOSCH ALTERNATOR
13-17
EJ
REMOVAL AND INSTALLATION
REMOVAL
&
INSTALLATION
REMOVAL
1.
Disconnect the battery ground
cable.
2.
Loosen the alternator
mount-
ing bolts and remove the adjust·
ment arm to alternator bolt. (Bet-
ter access to these may be possible
with the vehicle raised)
.
3.
Disengage the alternator belt.
Remove
the
alternator
mounting
bolt, disconnect the alternator
wir-
ing- harness and remove the
alter-
nator.
INSTALLATION
1.
Attach
the
alternator
wiring
harness.
Position the alternator to the
engine, and install the alternator mounting
bolt
finger-tight.
EJ
MAJOR REPAIR OPERATION
DISMANTLING THE ALTERNATOR
1.
Mark both end housing and the
stator with a scribe
mark.
2. Remove the brush holder by
unscrewing the 2 attaching screws.
3.
Remove the 4 through
bolts.
4.
Separate the drive end head
and rotor sub-assembly from the slip
ring end head and stator
sub-assembly.
Do not loose the wave washer from
the slip ring end head bearing recess.
5. Using long nose pliers on the
diode leads as heat sinks unsolder
the 3 stator leads from the rectifier
assembly and remove the stator.
6.
Remove the 4 attaching screws
and withdraw the rectifier assembly
from the slip ring end
head.
7.
To remove the rotor from the
drive end head hold the rotor in a vice
equipped with soft jaws. Remove the
pulley retaining nut
,
lock washer,
spacer and pulley. Remove the second
spacer and the fan. A third spacer
(shouldered) is fitted in the end
head, remove this spacer.
8. The end head may now be
supported on a press and the rotor
pressed out. A shouldered spacer
will be found on the shaft behind
the
bearing.
:..:
.
9. Remove the drive end head
bearing by unscrewing the 2 retaining
plate screws,
re~ove
the plate and
withdraw the bearing.
10. Remove the bearing from the
slip ring and of the rotor shaft with
a suitable puller.
11. For cleaning and inspection
see Part 1 of this group.
ASSEMBLY
1. Position the drive end head
·bearing, shielded side first, in the end
head. Secure the retaining plate with
two screws.
2. Place the smaller of the two
shouldered washers on the drive end
of the rotor shaft with the shoulder
towards the
bearing.
(Make sure that
the jump ring has not been displaced
on the shaft.)
3.
Push the rotor shaft through
the bearing. (This should be a hand
push fit.)
4. Place the larger shouldered
spacer on the rotor shaft with the
shoulder toward the bearing.
5.
Position the fan on the shaft
with the blades toward the end head
and follow it with a spacer, pulley,
lock washer and-nut.
6. Grip the rotor in a vice equipped
,·:·
2.
Install
the
adjustment arm t
o
a
lternator bolt.
3.
Adjust th
e
belt tension
using·
tool T63L-8620-A
.
Apply
pressure
on
the
alternator
front
housing
<'
nly,
when
ti
g
htening
the
belt.
Tig
hten
t
he adjusting arm
bolts
and the mounting
bolt.
4.
Lower the car and connect the
batte
r
y g
round
cable.
with soft jaws and tighten the pulley
nut to
specification.
7. Press the slip ring end bearing
onto the shaft shielded side first
.
8.
Position the rectifier pack in
the slip ring end
head.
Insert the
two long screws in the insulated
holes and the two short screws in the
other two mounting holes. Tighten all
screws.
9. Position the stator assembly on
the slip ring end head and align the
scribe marks.
10.
Using a pair of pliers as a heat
sink on the diode leads quickly solder
the stator leads to the terminal strips
on the rectifier
pack.
11
.
Place the wave washer in the
slip ring end head bearing recess.
12.
Fit the rotor end head and
rotor sub-assembly to the slip ring
head and
·
s tator sub-assembly, align
the scribe marks and fit the through
bolts.
13.
Tighten
the
through bolts
evenly.
14.
Fit the brush and terminal
assembly and tighten the attaching
screws.
15. Ensure that the rotor turns
freely by hand, install on the vehicle
and observe operation.
FIG. 21 - Rectifier Pack Fixing Screws
FIG. 22 - Soldering Stator Leads
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