Repair Procedures

Replacement

1. Disconnect the battery negative terminal first, then the positive terminal.
2. Temporarily loosen the water pump pulley bolts.




3. Remove the alternator drive belt(A) , after loosening the adjusting bolt and mounting bolt.
4. Remove the power steering pump belt(B).




5. Remove the water pump pulley.
6. Remove the power steering pump.
7. Remove the power steering pump bracket.
8. Disconnect the alternator connector (A), and remove the cable (B) from alternator "B" terminal.




9. Remove the adjusting bolt (A) and mounting bolt (B).
10. Remove the alternator brace(C).
11. Pull out the through bolt (D) and then remove the alternator (E).




12. Installation is the reverse order of removal.
13. Pretighten the water pump pulley bolts.
14. Adjust the power steering pump belt tension.
15. Adjust the alternator belt tension after installation.
16. Tighten the water pump pulley bolts.

Disassembly

1. Remove the alternator cover(A) using a screw driver(B).




2. Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).




3. Remove the slip ring guide(A).




4. Remove the nut, pulley(A) and spacer.




5. Loosen the 4 through bolts(A).




6. Disconnect the rotor(A) and cover(B).




7. Reassembly is the reverse of disassembly.

Inspection

Rotor
1. Check that there is continuity between the slip rings (A).




2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (C).
3. If the rotor fails either continuity check, replace the alternator.

Stator
1. Check that there is continuity between each pair of leads (A).




2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the generator.

Alternator Belt Inspection And Adjustment

NOTE:
When using a new belt, first adjust the deflection or tension to the values for the new belt, then readjust the deflection or tension to the value for the used belt after running engine for five minutes.

Deflection method:
Apply a force of 98N (10kg, 22lb), and measure the deflection between the alternator and the water pump pulley.

Deflection
Used belt: 4.2 - 4.7 mm (0.1654 - 0.1850 in)
New belt: 3.3 - 3.7 mm (0.1299 - 0.1457 in)

NOTE:
If the belt is worn or damaged, replace it.





Belt tension gauge method:
Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions.

Tension
Used belt: 392.3 - 490.3N (40 - 50kg, 88.2 - 110.2lb)
New belt: 637.4 - 735.5N (65 - 75kg, 143.3 - 165.3lb)

NOTE:
If the belt is worn or damaged, replace it.





If adjustment is necessary:
1. Loosen adjusting bolt (A) and the lock bolt (B).
2. Move the alternator to obtain the proper belt tension, then retighten the nuts.




3. Recheck the deflection or tension of the belt.

NOTE:
For the power steering pump belt and A/C compressor belt adjustments, refer to power steering pump in ST Group and air compressor in HA Group.