Compact Alternator, Assemble (Bosch)
Place rear bearing on armature shaft and press over bearing inner ring to stop on insulator (1) using suitable sleeve.
If pressure is too high, the insulator may be damaged!
Support armature shaft via rear bearing inner ring with suitable sleeve (see illus. II). Slide bearing cap (4), front bearing (3) and spacer (2) onto armature shaft and carefully press on to stop with suitable sleeve.
Note installation position of bearing cover. If pressure is too high, the insulator may be damaged!
Insert dust cap into rear housing.
Ensure retaining tabs are inserted in guide (see illus. I).
Install armature shaft in front housing (see illus. II).
Bolt bearing cover to front housing (1, see illus. III).
Attach front housing to armature shaft and rear housing (see illus. I). Note marks on housing halves!
Insert through bolts (1, see illus. II) into alternator and screw housing halves together.
Through bolts to alternator 4 - 6 Nm / 3-4 lbf. ft.
Clip electronic regulator with brush holder into rectifier bridge (see illus. III) and screw together.
Note carbon brushes when installing electronic regulator. Risk of breakage!
Install rear housing cover (arrows).
Install pulley to armature shaft. Counterhold pulley with commercially available locking band (see illus.).
Pulley nut to armature shaft - 65 � 5 Nm / 48 � 4 lbf. ft.