- Assemble the generator cover from the drive side. To do this, press the bearing with the sealed side towards the rotor. Screw three bolts into the generator cover.
- Install the rotor into the rotor cover. To do this, you need to insert a spacer ring and press the rotor in. The rotor cover should be positioned properly. Insert the spacer sleeve on the outside of the rotor shaft and mount the rotor to the belt pulley.
- Tighten the nuts to a torque of 60 Nm. The rotor can be carefully clamped in a vice with soft metal jaws.
- If the wires were unsoldered, they need to be soldered again. In this case, electrode pliers are used for heat dissipation; they need to be placed on the connecting pins of the diodes so that they do not overheat.
- Check the inside of the stator and turn any loose wires on their sides so they cannot touch the rotor.
- Insert a small wire into the location shown in the picture 252 place through the rear wall of the brushless generator to hold the brushes in the raised position.
Figure 252. Assembling a brushless alternator
- Press the contact ring of the cover onto the rotor.
- Install the contact ring through the stator and the generator cover from the drive side, making sure that the brushes do not touch the contact rings,
- The pin installed to secure the brushes must now be removed.