I have come across the necessity to know the content of various "Bosch(tm) Application Notices from their Reman Catalog, which are referred to in parts descriptions of many Bosch Alternators and Starters, and I have had difficulty finding these Notices.
These notices are necessary in order to know which replacement part to order, especially when changes have been made to the parts over the years.
In the hopes that I can be of service to other mechanics who have the same problem, I am building this list of the Application notices that I can find. For now, I will only list the text portions of the notices. Even without the illustrations, just knowing the content of the Notice could help you decide what to do.
These notices are referred to on numerous part source websites in regard to possible part substitutions.
Application Notice B-12
When mounting Delco starters the distance between the starter drive teeth and the flyheel must be checked to insure proper alignment. The clearance must be within a specified range to avoid such problems as excessive starter noise, broken flywheel teeth, damaged starter drive teeth, or burned out solenoid or armatures.
Remove lower flywheel housing cover and examine for visual problems (bent flywheel, uusual wear, broken teeth, etc.) Using a screwdriver, move the starter drive and clutch assembly so that the drive teeth and flywheel teeth are meshed. A drive tooth should be directly in the center between two flywheel teeth. With wire gauges .025" to .040" in diameter, measure the drive to flywheel clearance at three different points, 120 degrees apart, making sure that the gauge is centeredIf clearance is under .020" shims should be added between the starter and cylinder block. A clearance of .060" at any of the three locations may indicate an excessively worn flywheel, indicating it should be replaced. (Drawings accompany this notice.)
Application Notice B-13
SR37X comes with or without threaded mounting holes in the flange. If you receive the unthreaded version, use the attached nuts and lockwashers; if you receive the threaded version, discard the old nuts and lockwashers.
Application Notice B-14
AL223X is a "B" circuit unit for use on vehicles with "B" circuit mechanical voltage regulators. To assure proper application, make certain the erminals of the original alternator are as shown in the diagram. Improper application may damage wiring or voltage regulator. (The three lines below are arranged the way the terminals should be arranged, one horizontal and two vertical below it.)
__ F
| E | N
Application Notice B-16
Alternators between 1983 and 1993 came equipped with one of two possible voltage regulators, with or without battery temperature sensing. Proper vehicle operation and alternator charging does not require this feature be connected, as the chafging system will work using the internal temperature regulation of either type. (drawing of the two types, with additional connecting posts on the back of the type WITH battery temp. sensing)
Application Notice B-20
Replacement of the back cover duct is very important to ensure proper cooling. If the connecting air hose is split, torn or damaged, it must be replaced. Premature failure of the Alternator due to overheating will be caused by not following the described procedure and will void the warranty. There are two different Original Equipment Alternators used for this vehicle, S.E.V.Marchal and Paris=Rhone. The back cover/air duct will not interchange between the two different types.
If the Paris=Rhone alternator is used, the following Porsche parts are required:
Porsche part number
928 803 133 04
928 603 135 02
928 612 865 02
Application Notice B-22
The original alternator with the post-type termination is no longer available. The later model alternator, with spade-type termination, has been approved as a direct replacement.
Alternator Removal: Follow this procedure for removing the original alternator. Disconnect the negative (-) battery terminal.
Pay careful attention to tag or mark each wire before removal.
1) Cut eyelet terminals from original wiring harness
2) Carefully trim insulation from wire ends of original harness to expose approximately 1/2" of fresh wire.
3) Twist like wires together from new harness adapter to new wiring harness.
[there is an illustration of the new connector]
4) Solder, then tape of shrink wrap the connections to prevent shorts or corrosion.
5) Follow remaining installation instructions on enclosed sheet and complete by plugging in new harness adapter to alternator and attaching B+ cable from wiring harness to B+ post of alternator.
Re: Application Notic #B-23 in the Bosch reman catalog for those who want to substitute an alternator with a built-in solid state regulator, for an original setup that used an external regulator, in Volvos and Mercedes of the late 1970s:
Notice B-23 basically says connect D+ from the harness (red wire) to D+ on the alternator. Connect the output (big gray wires) in the same way as the old alternator. Ignore DF and DE (black and yellow) on the harness.
Application Notice B-23
This Alternator is fitted with an internal Voltage Regulator and will improve the overall charging system. It will eliminate the need for the originally fitted external voltage regulator.
To Replace External Regulators with Internal Regulators
1) Disconnect negative battery cable from battery
2) Remove the plug from the external regulator and locate the D+(61) wire. This is the wire which causes the red dash indicator light to glow when grounded with the key on, engine off. The terminal designations may also be identified by referencing the terminal block, where the designations are molded into the side where the wire enters.
3) This wire terminates at both the alternator and eternal regulator. When connecting the replacement internally regulated alternator, this wire should be connected to the D+(61) terminal of the alternator and remain disconnected at the old regulator
4) The remaining DF & D- wire is no longer required and will remain disconnected. This remainiing wire can be removed or secured out of the way with the D+(61) wire going to the old regulator.
5) Connect the battery lead to the battery terminal of the alternator. Modification is now complete.
6) Check fan belt and tension as required. Reconnect battery cable to battery. Verify operation of the red dash indicator light before starting engine. Check alternator output and regulator voltage.
(a diagram of the above steps was included with this Notice.)
The following Notices are only partially represented here at this time:
Application Notice B-37
Toyotas may exhibit a gear clash or grinding noise during cranking. To correct this problem Toyota has introduced a new and improved starter drive pinion gear and flywheel ring gear. Both parts have been updated by changing the chamfer/bevel on the teeth of the gears. All Bosch remanufactured starters for these Toyota applications are uilt with the new style beveled starter drive pinion gear.
When replacing your original starter, inspect the flywheel for abnormal wear or lack of bevel of the ring gear teeth. If the vehicle does not have the late style beveled tooth gear ring or is damaged, replace the existing flywheel with the new beveled tooth flywheel available from your local Toyota dealer.
Application Notice B-45
Some early model Volkswagen, Porsche and Saab vehicles may experience a condition where the starter motor cranks slowly or not at all upon the activation of the ignition switch.
If after installing this replacement starter the vechile still exhibits a hard start condition, it is suggested that you inspect the condition of the electrical system for averall wire quality and integrity (i.e.
Application Notice B-49
Chrysler and Mitsubishi vehicles equipped with Mitsubishi Alternators may exhibit a condition where the Alternator will not charge or fail prematurely
Application Notice B-78
1986 Mazda B2000 pickups
Application Notice B-79
1979-85 Mazda RX7s may suffer from a variety of charging and sarting problems due to a unique "mid-cable" ground connection. The battery ground cable is grounded at a chassis bolt on the left front strut tower before continuing on. If this connection gets corroded,
Application Notice B-85
1985-90 Volkswagen Golfs, Passats and Jettas may exhibit low alterntor output, alternator charge light on, or squealoing belts when driven in wet conditions. To correct this condition, Volkswagen has released splash sheilds to be installed over the drive belts to protect them from moisture and prevent the belts from slipping which causes the low alternator output and squeling belts. Splash shield #191 0250 01C should be used for Golfs and Jettas, and #357 825 254 for Passats.
Application Notice B-102
Most late model Chrysler, Dodge Eagle, Jeep and Plymouth vehicles with Nippondenso alternators have external voltage regulators which are contained in the ECU. When it appears that the alternator is no longer functioning properly, quite often it is the voltage regulator in the ECU which is malfunctioning
Application Notice B-111
Removal or Installation of the Delco CS Series Alternator
1) Disconnect the negative battery cable.
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