Repairing 45 AMP. and 65 AMP. alternators (Bosch version) — VW

Ball bearing (slip ring side)
Removing => fig.
4
Installing - press inner race on to the stop - always renew bearing. Bearing is encased on both sides.

Rotor
Different versions for 45 Amp. and 65 Amp. generators
Checking: => fig.
9
Removing: => fig.
5

Voltage regulator/carbon brushes
R + I => fig.
3

Voltage regulator
Checking => page
27-22

Spring clip

Generator housing
Mark position in relation to end plate

Diode plate
Checking => fig.
10
Removing => fig.
6
When renewing install suppression condensor => fig.
1

Cheese head screws
Stator
Different versions for 45 Amp. and 65 Amp. generators
Removing => fig.
6
Checking => figs.
7
,
8

Fan
Pay attention to direction of rotation, which is indicated by arrows

Belt pulley
Diameter 61 mm

35 Nm

Intermediate ring
Press on

End plate
Mark position in relation to generator housing
Watch out for different versions with regard to securing flange

Ball bearing (drive side)
Always renew bearing

Fig.1
Suppression condenser connection

Fig.2
Removing and installing voltage regulator

The voltage regulator can be removed with the generator in situ

Fig.3
Removing and installing carbon brushes

a = new = 10 mm, wear limit = 5 mm.

If necessary unsolder carbon brush wires (arrows)

From the 1981 Model Year an improved voltage regulator (Hybrid regulator) with longer carbon brushes has been installed in production

Carbon brush lengths:

new approx. 13 mm
Wear limit approx. 5 mm

Note:

When a new voltage regulator (Hybrid) has to be renewed, it is not permissible to install another type of regulator because of the longer carbon brushes. Particular attention must be paid to the Part No.

The slip ring diameter has been reduced from 32 to 28 mm.

The shape of the generator housing openings has been altered. The narrow slots prevent the ingress of foreign bodies.

Fig.4
Removing ball bearing

A -
Separating appliance e.g. Kukko 15/0 or 17/0
B -
Puller e.g. Kukko 18/0

Fig.5
Removing rotor - Three arm puller

Messrs. Schrem Order No. 57-036

or

Messrs. MATRA Order No. V 158

Note:

The three arm puller must grip behind the bearing plate otherwise the screws will either be torn out or sheared.

Fig.6
Removing and installing stator/diode plate

Use long nosed pliers to dissipate heat.

Fig.7
Checking stator/earth short

Measuring instrument: V.A.G 1315 A

Press button for resistance measurement.
Connect probes to the measuring points 1 and 2; 1 and 3; 1 and 4 in turn.

A flashing resistance reading must be indicated in the Kω range.

Fig.8
Checking stator/winding short

Measuring instrument: resistance measuring bridge

Connect test probes to winding ends 1 and 2; 1 and 3; 2 and 3 in turn. At each measurement the following values should be indicated:

45 Amp. generator - 0.18 up to 0.20 ω
65 Amp. generator - 0.10 up to 0.11 ω
Where results differ renew stator.

Fig.9
Rotor/earth short

Measuring instrument: V.A.G 1315 A

Press button for resistance measurement.

A flashing resistance reading must be indicated in the Kω measuring range.

Fig.10
Checking diode plate

Measuring instrument: VW 1315 A

Unsolder stator windings. Press resistance and voltage measuring buttons simultaneously.
Checking plus diodes: place black test probe on positive heat sind -1- (the same as B+) and the red probe to the collection points -2- one after the other.
Checking minus diodes - place rec probe to negative heat sink -3- and black probe to collection points -2- one after the other.

Checking exciter diodes:

Place black probe onto contact rail -4- (the same as D+) and red probe to collection points -2- one after the other.

The indication for all tests must be 3 times 50 - 80 ω. If this is not the case, renew diode plate.