Alternator - BOSCH: Overhaul: Disassembly

With alternator removed, place alternator assembly mounting lug in a soft-jawed vise. Loosen pulley nut and remove lock washer. See Fig 1.

Fig 1: Exploded View of Alternator With Internal Regulator Check alternator for proper output. If not to specifications, disassemble and retest.
Remove alternator pulley, pulley-to-fan spacer and pulley fan. Remove woodruff key from rotor shaft. Disconnect capacitor terminal, remove capacitor mounting screw and capacitor.
Remove voltage regulator and brush holder mounting screw. Remove regulator and brush holder. Remove "D+" stud nut, lock washer, stud washer and stud insulators. Remove battery stud nut, lock washer, flat washer and insulator.
Remove through bolts. Pry between stator and drive end shield and separate drive end shield, pulley and rotor assembly away from stator and rectifier end shield assembly.
Press rotor out of drive end shield. Remove spacer. Remove pulley fan spacer. Remove four alternator drive end shield bearing retainer screws and bearing retainer. Press out drive end shield bearing. Remove front drive bearing from front drive end shield.
NOTE: Use a pair of needle nose pliers as a heat sink during any soldering operations.
Unsolder stator-to-rectifier leads. Scribe line on stator coil frame. Remove stator from rectifier end shield assembly. Remove three rectifier assembly mounting screws and remove stator assembly.
Remove inner battery stud insulator. Remove "D+" stud insulator, stud nut, stud flat washer and insulating washer. Remove rear bearing oil and dust seal. Check rotor bearing surface for scoring. Remove rear rotor bearing with puller (C-4068 or C-4333).

NOTE: During cleaning and inspection, DO NOT immerse stator field coil assembly, rotor assembly or rectifier assembly in cleaning solvent. Immersing these assemblies will damage parts. Clean with moist cloth only and wipe dry.