Bosch Compact Alternator, Disassemble and Reassemble
Bosch Compact Alternator, Disassemble and Reassemble
Important!
Before disassembling the alternator, mark position of the casing front and rear parts with respect to the stator. Do not damage leading-out wire of the stator winding.
Disassemble
Release fastening nut for pulley - counterhold pulley with flat wrench. Remove pulley from armature shaft.
Remove fastening nuts (1) from housing cover. Remove housing cover from alternator.
Unscrew fastening bolts (2) from electronic regulator.
Disassemble
Unclip electronic regulator sideways from retaining lug with suitable tool.
Important!
When removing the electronic regulator pay attention to carbon brushes. Risk of breakage.
Disassemble
Mark position of the casing halves with respect to one another.
Unscrew through-bolts (1) from alternator.
Disassemble
Detach rear casing half with rectifier bridge and stator winding from front casing half.
Unscrew bearing cover bolts (1) from front casing half.
Pull armature shaft with bearings out of front casing half.
Disassemble
Disconnect dust cover from rear bearing.
Important!
Detach bearing from the armature shaft only if defective. Bearings detached from the armature shaft must not be reused.
Disassemble
Disconnect rear bearing from the armature shaft with suitable claw remover.
Detach spacer (1), front bearing (2) and bearing cap (3) from the armature shaft with a claw remover.
Assemble
Position rear bearing on armature shaft and press on with appropriate sleeve over bearing inner race until it rests against the insulator (1).
Important!
The insulator will be damaged with an excessively large contact force.
Assemble
Support armature shaft above rear bearing inner race with appropriate sleeve. Slide bearing cover (4), front bearing (3) and spacer (2) onto armature shaft and carefully press on with appropriate sleeve until the stop.
Important!
Note installation position of the bearing cover. Insulator will be damaged with an excessively large contact force.
Assemble
Insert dust cap into rear housing half - ensure that retaining lugs are inserted into guide.
Slide armature shaft into front casing half.
Bolt on front housing half using fastening bolts (1) with bearing cap.
Assemble
Join front casing half with armature shaft and rear casing half. Note mark on casing halves.
Insert through-bolts (1) into alternator and bolt housing halves together - tightening torque 5 Nm / 4 lbf. ft.
Clip electronic regulator with brush holder into rectifier bridge and bolt together.
Important!
When installing the electronic regulator pay attention to carbon brushes. Risk of breakage.
Assemble
Fit rear casing cover (arrows).
Fit pulley onto armature shaft. Counterhold pulley with flat wrench - tightening torque 65 Nm / 48 lbf. ft.
Important! 
Disassemble 
Assemble 
