Disassembly and Assembly

GENERATOR ASSEMBLY

DISASSEMBLY AND ASSEMBLY [2.0L ENGINE NON-TURBO, 2.4L ENGINE]

Disassembly Steps 1-15:

Required Special Tool:
- MB992226: Serration Socket


DISASSEMBLY SERVICE POINTS

[A] PULLEY REMOVAL







1. Set the special tool MB992226 to the pulley.







2. Set the closed wrench to the hexagonal area of the special tool MB992226.







3. Insert the hexagonal bit socket having width across flats of 10 mm into the hexagonal area of the rotor shaft.
4. Hold the pulley with the closed wrench. Rotate the rotor shaft clockwise to remove the pulley.

[B] FRONT BRACKET REMOVAL







CAUTION: Do not insert the screwdriver blades too deep. Doing so could damage the stator coil.

Insert the blades of screwdrivers between the front bracket and stator core, and pry and separate them with the screwdrivers.

[C] STATOR/REGULATOR ASSEMBLY

REMOVAL







CAUTION:
- Use a 180 - 250 W soldering iron, and finish unsoldering within four seconds. Diodes will be damaged by heat if unsoldering time is too long.
- Avoid applying undue force to the diode leads.

1. Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the regulator assembly, undo the soldered points on the rectifier assembly.

REASSEMBLY SERVICE POINTS

[A] REGULATOR ASSEMBLY INSTALLATION







After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.

NOTE: Holding the brush with the wire facilities installation of the rotor.

[B] ROTOR INSTALLATION







Remove the brush holding wire after the rotor has been installed.

[C] PULLEY INSTALLATION

1. Clean the inner race of the front bearing and that of the pulley.







2. Screws the inner race of the pulley until it touches the inner race of the front bearing.







3. Set the special tool MB992226 to the pulley.







4. Set the closed wrench to the hexagonal area of the special tool MB992226.







5. Insert the hexagonal bit socket having width across flats of 10 mm (0.4 inch) into the hexagonal area of the rotor shaft.
6. Hold the pulley with the closed wrench.
Rotate the hexagonal bit socket counterclockwise to tighten it to the specified torque.

Specified torque: 73 ± 12 N.m (54 ± 8 ft-lb)