101602-7533 ZEXEL 9 400 614 903 BOSCH INJECTION-PUMP ASSEMBLY 9400614903 1016027533 1156026873

Disassembling alternator(2) Removing Pulley(a) Wrap cloth around the rotor, then clamp the rotor in a vise. Remove the pulley nut and then the pulley and spacer.(b) Pull the rotor out of the front bracket.
Removing pulley(3) Removing Stator and Rectifier(a) Unsolder from the rectifier the leads that connect the rectifier to the stator coils. Then, remove the stator.
Unsolder the leads quickly to prevent heat from damaging the diodes.
(b) Remove the rectifier's mounting screws, then remove the rectifier.
Removing stator3.4 Inspection KEY POINTS FOR INSPECTION(1) Inspecting RectifierWith each diode, measure the resistance between the diode terminal and the heat sink. Measure the resistance with the tester's (+) probe applied to the diode terminal and with the tester's (-) probe applied to the diode terminal. If the resistance is infinite in both cases, there is an open circuit. If the resistance is close to zero in both cases, there is a short circuit. An open circuit or short circuit indicates a diode fault. Replace the rectifier if any diode is faulty.Next, measure the resistance between the terminals of the leads that connect the rectifier to the stator coil for each of the diodes. If any measurement reveals an open circuit (infinite resistance) or a short circuit (near-zero resistance), replace the rectifier.
Inspecting rectifier(2) Inspecting Field Coil(a) Check whether continuity exists between the rotor's slip rings. If continuity does not exist, the field coil is open-circuited and the rotor must be replaced.
Field coil continuity test(b) Check whether continuity exists between each slip ring and the rotor shaft (or core). If continuity exists, the field coil is grounded and the rotor must be replaced.
Field coil ground test(3) Inspecting Stator Coils(a) Check whether continuity exists between the leads at the ends of each stator coil. If continuity does not exist between any coil's leads, there is an open circuit and the stator must be replaced.
Stator coil continuity test(b) Check whether continuity exists between each stator coil lead and the stator core. If continuity exists, the stator coil is grounded and the stator must be replaced.
Stator coil ground test(4) Inspecting Brushes(a) Replace the brush if it is worn down to the wear limit line.
Inspecting brush(b) To replace the brush, remove the cover (see the drawing) then unsolder and take out the brush set.
Replacing brush3.5 AssemblyPerform assembly by following the disassembly sequence in reverse. KEY POINTS FOR ASSEMBLY(1) Heat the rear bracket before press-fitting the rear bearing into it. Do not apply oil or grease to the outer or inner surface of the bearing.(2) Before fitting the rotor in the rear bracket, insert a thin metal rod into the small hole in the rear bracket to keep the brushes raised. Remove the metal rod when assembly is complete.
Assembling alternator3.6 InstallationPerform installation by following the removal sequence in reverse. KEY POINTS FOR INSTALLATION Insertion of spacer and clearance adjustmentInstallation of the support bolt is accompanied by insertion of a spacer. Install the spacer as follows:(a) Insert the support bolt into pinion. (Do not install the nut.)(b) Install the alternator