Repair Procedures
Removal
1. Disconnect the battery negative terminal.
2. Disconnect the air compressor connector (A) and the alternator connector (B), and remove the cable from alternator "B" terminal (C).
3. Loosen the mounting bolts, and then turn the adjusting bolt (A) clockwise to loosen tension.
4. Remove the drive belt (A).
5. Remove the alternator (A) after remove the mounting bolts.
Installation
1. Install in the reverse order of removal.
2. Adjust the alternator belt tension after installation.
Alternator installation bolt:
[12mm (0.47in) bolt]
19.6 - 26.5 Nm (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
[14mm (0.55in) bolt]
29.4 - 41.2 Nm (3.0 - 4.2 kgf.m, 21.7 - 30.4 lb-ft)
Disassembly
1. Remove the rear cover (A) after removing nuts.
2. Remove the mounting bolts (A) and the brush holder assembly (B).
3. Remove the slip ring guide (A) after pulling it.
4. Remove the OAD(Overrunning Alternator Decoupler) cap.
NOTE:
- When installing, replace with new OAD cap.
5. Remove the OAD(Overrunning Alternator Decoupler) pulley (A) using the special tool.
6. Remove the nut and pulley(A). (NON- OAD)
7. Unsolder the 3 stator leads (A).
8. Remove the 4 through bolts (A).
9. Disconnect the rotor (A) and bracket (B).
Reassembly
1. Reassemble in the reverse order of disassembly.
NOTE:
- When reassembling OAD pulley, replace with new OAD cap.
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.
Drive belt tension measurement and adjustment
Belt tension measurement
Measure the belt tension using a mechanical tension gauge or a sonic tension meter.
Tension
[Without OAD]
New belt: 882.6 - 980.7N (90 - 100kg, 198.4 - 220.5lb)
Used belt: 637.4 - 735.5N (65 - 75kg, 143.3 - 165.3lb)
[With OAD]
New belt: 686.5 - 784.5N (70 - 80kg, 154.3 - 176.4lb)
Used belt: 490.3 - 588.4N (50 - 60kg, 110.2 - 132.3lb)
CAUTION:
- If the engine has run for 5 minutes or more, the belt tension must be adjusted as a used belt.
- When installing the V-ribbed belt, all grooves on the pulley should be covered with belt ribs.
- A loose belt causes slip noise.
- Too tight belt cause bearing of alternator and water pump to damage.
Using a mechanical tension gauge (BT-33-73F, BTG-2 type)
1. While pressing the handle (A) of the gauge, insert the belt (B) between pulley and pulley (or idler) into the gap between spindle (C) and hook (D).
2. After releasing the handle (A), read a value on the dial pointed by the indicator (B).
Using a sonic tension meter (U-505/507 type)
1. Input the belt specifications into the tension meter.
NOTE:
Measurement of S (Span) : Calculate average value after measuring the distance 3 - 4 times.
D : Idler
d : Alternator pulley
2. Locate the micro phone (B) close to the center of belt span (A) and bounce the belt by finger 2 - 3 times. Read a value on the display.
[With A/C]
[Without A/C]
If adjustment is necessary:
1. Loosen the mounting bolts (A).
2. Tighten the adjusting bolt(B) clockwise in loose tension ; loosen the bolt counterclockwise in high tension.
3. Recheck tension of the belt.
4. After adjusting tension, tighten the through bolts.
Tightening torque
12mm (0.47in) bolt :
19.6 - 26.5 Nm (2.0 - 2.7 kgf.m, 14.5 - 19.5 lb-ft)
14mm (0.55in) bolt :
29.4 - 41.2 Nm (3.0 - 4.2 kgf.m, 21.7 - 30.4 lb-ft)