LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> BMW >> 1971 >> 3.0CSL Automatic Trans >> Repair and Diagnosis >> Electrical >> Charging Systems >> Alternators - BOSCH >> Overhaul >> Reassembly & Testing
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Reassembly & Testing

  1. On all except 0 120 400 600 series alternators (steps 1  through  4), fit negative diodes heat sink and clamps. Screw in double end bolts (shorter threads outward).
    NOTE: Left clamp is longer than right.

    Replace insulating washers and bushings. Test terminal bolt "B+" for short circuit to ground. Test voltage should be 80V AC.

  2. Position positive diodes heat sink (carrier) and secure with insulating and spring washers.
    NOTE: Use insulating cap No. 1 120 502 000 instead of insulating washer on bolt next to terminal marked "D +/61".

    Tighten hex nuts.

  3. Place stator in slip ring end frame. Draw positive and negative diode leads together and slip through an insulating sleeve. Push sleeve over lead of exciter diode and stator connection cable. Crimp a metal ring around end of leads and solder. Cut off any excess wire protruding through ring. Reposition wiring and attach in holding clamps.
  4. Slide insulating sleeve over exciter diode terminal. Insulating sleeves of stator connection lead must project over edge of negative diodes heat sink. Clamp connections firmly.
  5. On 0 120 400 600 series alternators (steps 5  through  7), test both "B+" terminal bolts for short circuit to ground. Test voltage should be 80V AC. Before fitting exciter diodes heat sink (carrier), solder three positive diode terminal leads onto heat sink from below.
  6. After fitting exciter diodes heat sink, solder stator leads, negative and exciter diodes to the "COMB".
    NOTE: Use caution, do not overheat negative diodes.

    Install brush holder. Raise and secure carbon brushes before installing. Screw conductor "D+" onto exciter diodes heat sink.

  7. Place wave spring washer into ball bearing fit. Rub ball bearing seat with suitable lubricant. Insert rotor with drive end bearing into slip ring end frame and secure with screws. Position positive diodes heat sink and secure. Springs are to be set onto carbon brushes by pressing on brush with a screwdriver. Brush springs pressure will seat brushes automatically.
  8. Rub suitable lubricant into ball bearing seat of slip ring end frame. Install claw pole rotor with drive end frame. Check position of stator relative to end frame. Position brush holder plate. Tighten screws. Install fan belt pulley. Coat newly installed positive diodes with chlorinated rubber lacquer.
scientia non olet · About LEMON Manuals