Overhaul

Disassembly

1. Remove the alternator cover(A) after removing three nuts(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 alternator.

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 values for the used belt after running engine for five minutes.

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

Deflection
Used Belt : 5.1 - 6.0 mm (0.20 - 0.236 in)
New Belt : 4.0 - 4.4 mm (0.15 - 0.173 in)

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




Belt tension gauge method :
Follow the gauge manufacturer's instructions, install the belt tension range. (Measurement may be done at any pulley span)

New Belt :686 ± 49 N (70 ± 5 kgf, 154 ± 11 lbf)
Used Belt :441 ± 49 N (45 ± 5 kgf, 99 ± 11 lbf)

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




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




3. Recheck the deflection or tension of the belt.