Alternators & Regulators 3-4 BOSCH ALTERNATORS Audi Porsche ON VEHICLE TESTING BMW Saab Fi Volkswagen = Off vehicle testing is included in Overhaul procedures Fiesta Volvo in this orticle. Mercedes-Benz DESCRIPTION ING CONTINUITY TEST Bosch alternators are conventional 3 phase, self rectifying type alternators, Nine rectifier diodes are connected to stator windings (3 to each phose lead). Diodes change alternator A.C. voltages to D.C. voltages coming out of the "B+" and the "D4" terminals of the alternotor ‘APPLICATION Model Volts/Amps Bosch Part N Audi +4900 Stondord 14/35 489 520 Heavy Duty 14/65 489 713 Californie 14/35 469 502 5000 Gosoline & Diesel... 14/35 499 502 Gasoline Only 14/55 489 653, Gotoline & Diesel. 14/65 489613, All With A/C 14/90 489 514 BMW 320% 14/65 489718 528i, 633C5i, 7931 0. 14/65 489 619 Fiot Brovo & Spider Standard 14/35 489 743 With A/C 14/65 1489 824 Fiesto 14/35 489 667 Mercedes Benz 2400 14/55 489 556 280 Series 14/35 48975) 300 Ser 14/55 489 527 300 Turbo 14/35, 489 683 450 Series 14/70 489 898 Porsche 924 14/75 469 502 Saab 99 14/55 489 783 300 14/55 489735, Volkswagen Dasher Gozoline 14/55 499 622 Diesel cnn 14/55 “489 520 Colit,@ All With A/C 14/65. 489713 Jetta, Rabbit & Scirocco Stondard 14/45 489 858 With A/C 14/65 499713 Rabbit Diesel Stondard 14/35 489 799 With A/C 14/65 489712 Vonagen 14/65 489913 Volvo DL& GT Stondard 14/35 400933 Heavy Duty. 14/70 450 009 Diesel 14/55 ‘1257294 © ~ Bosch part numbers are preceded by 0 120 for alternators. Integral regulator models ore num bered 469 and 489, while separate regulator models are numbered 400 ond 450, © = Volvo part number Disconnect terminal plug from rear of alternator and connect & voltmeter negative terminal to ground. With ignition "ON", connect positive lead to each of the connector wires in turn Voltmeter should read bottery voltage as each positive connec: tion is made. If proper voltage is not read, trace each wire 10 find foul VOLTAGE DROP TEST ~ GROUND SIDE Connect voltmeter between negative terminal of battery and alternator housing. Start engine and run at approximately 3000 RPM. If volimeter reading exceeds .25 volt, o high resistance in negative side of charging circuits indicated. If 50, check for loase, dirty or corroded connections ‘ourpur Test Disconnect terminal plug from rear of alternator and connect ‘ommeter in series between olternator center terminal ond corresponding socket in terminal plug. Connect a jumper lead between the "D+" terminal and its corresponding socket in ter- minal plug. Stort engine and run at epproximately 3000 RPM. Turn on headlights ond leave on for 5 minutes. Ammeter should read maximum alternator amperage at normal operating temperature, REGULATOR CONTROL VOLTAGE TEST Connect voltmeter between battery terminals. Connect om: meter in series between "B+" terminal of alternator and corresponding terminal of connector plug. Connect o jumper lead between slternator "0+" terminal and corresponding terminel of connector plug. Start engine and increase speed to ‘approximately 3000 RPM. Run engine until charging rote falls below 3-5 amps. Voltmeter should then read 13.7-14.4 vols. If these readings are not obtained, replace regulator. — Test cables should not be removed or load ex cessively reduced during testing procedure. Considerable load voriations may damage the diodes, Control lamp should not 90 07 af ony time during the test. OVERHAUL DISASSEMBLY 1) Scribe mark for alignment on front and rear alternator housing, Remove nut, pulley, fan and key. Unscrew brush plate osiembly and remove from alternator. Remove frame bolts fond separate rear frame from front frame with rotor. Press rotor from frame and bearing from rotor. Remove insulation {rom wires ond cut wires as close to soldered joints as possible. = On 4XX 6XX series alternators, lift ond secure brushes prior to disossembly ‘ipo 200 Rapa ema CampaAlternators & Regulators 3-5 BOSCH ALTERNATORS (Cont. 2) Diodes may be tested at this point without further dis ‘ossembly. Use core with insulating bushings under positive diode carrier. To remove negative corrier, extract threaded studs. When one diode hos been damaged due to short ci cuiting, the 3 complementing diodes must also be replaced. Unserew nuts on both "B+" terminal bolts and lift positive carrier (heat sink) up and back TESTING AND REPAIRING Diode Assemblies ~ Test diodes with suitable tester before dismantling sip ring end frame, DO NOT lay positive diode corrier on housing oF 0 false reading will obtained. Disconnect condvctor from "+" to exciter diodes af heot sink, Unscrew spring and brush holder and remove from alternator. Unsolder Stotor lead and negative diode connections, Unicrow exciter diodes heat sink and remove together with postive diodes heat sink. Cleon ll components with gasoline or trichlorethylene prior fo further testing Stator ~ Test stator for short circuits to ground. Tester voltage: should be 40V AC. Measure resistance of stator windings bet ween phase connections. Fiesta should indicate .14..16 ohms, with all remaining models showing .20 0 .22 ohms. Rotor ~ Test claw pole rotor for short circuits to ground using 40V AC tester, Meature resistonce of exciter (field ceil) n rotor with ohmmeter across slip rings. Resistance should be 40-4.4 ohms. If necessary, turn slip tings in a lathe, nating maximum runout of 001" (03 mm) and minimum diameter of 1.25" (31.5 mm). Maximum pole wheel runovt should not exceed (002" (.05 mm) Diode Replacement ~ In cose diodes are found to be defec tive, entire diode plote assembly should be replaced. Core must be exercised in soldering near diodes due to possible domage from excess heat, Use flot jawed pliers os heat «ink ‘opplied to leads when soldering diode connections Cooling Boffle (Heat Sink) Fig. 1 Drive End Frame ~ Check boll bearings for wear and replace as necessary. Lubricate ball bearings on one side. Press ball beoring into drive end. frame with shielded side downward. Serew on retainer plote, Press ball bearing on slip, ring end of rotor ond press drive end frame onto drive end of Carbon Brushes — Minimum brush length is 2" (5 mm). If replacement is required, grip brush with flat-awed pliers and lunsolder brushes, Do not allow solder to run into strands of brush leads, Brush must be free to slide in holder with normal spring tension of 10-14 os. (283-397 g), REASSEMBLY 1) Solder stator ond diode connections using caution not to ‘overheat diodes. Place stator and diode assembly in rear hous ing ond secure with screws, 2) lubricate new sear bearing and press onto rotor shot, ‘osturing thot shielded side of bearing faces slip rings. Place front bearing in housing with shielded side rearward. Install retainer plate 3) Ploce spacer ring on rotor shalt ond install rotor ossembly inta front housing. Press front bearing retaining ring over shaft fond into front housing with @ socket 4) Coot bearing bore of rear housing with grease and instll spring wosher. Assemble front housing with rotor to rear hous: ing, vsing @ turning oF twisting motion to seat rear beoring Line up seribed alignment marks and instal screws through housing, 5) Instoll shaft key, washer, fan, spacer, pulley, lock washer fond nut. Install brash and connector plug assembly ond retain swith screws, Stator Winding Clowpole Rotor ‘Cutaway View of Bosch Alternator ‘ipo 200 Rapa ema Campa -Po-770mem