Repair Procedures

Removal and Installation

1. Disconnect the battery negative terminal first, then the positive terminal.

Tightening torque
(-) terminal :
4.0 - 6.0N.m (0.4 - 0.6kgf.m, 3.0 - 4.4lb-ft)
(+) terminal :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)

2. Loosen the mounting bolts (A,B)




3. Turn the adjusting bolt(B) clockwise in loose tension.




4. Remove the drive belt (A).




5. Disconnect the air compressor connector(A) and the alternator connector (B), and remove the cable (C) from alternator "B" terminal.




6. Remove the alternator(A).

Tightening torque
12mm (0.47in) bolt :
19.6 - 26.5 Nm (2.0 - 2.7 kgf.m, 14.5 - 19.5 Ib-ft)
14mm (0.55in) bolt :
29.4 - 41.2 Nm (3.0 - 4.2 kgf.m, 21.7 - 30.4 Ib-ft)




7. Installation is the reverse order of removal.
8. Adjust the alternator belt tension after installation.

Disassembly

1. Remove the rear cover (A).




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




3. Remove the slip ring guide(A).




4. Remove the pulley(A) using the special tool.




5. Unsolder the 3 stator leads(A).




6. Loosen the 4 through bolts(A).




7. Disconnect the rotor(A) and bracket(B).




8. Reassembly is the reverse order of disassembly.

Inspection

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




2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).
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 alternator.