Alternator¶

Removal of alternator¶

1. Disconnect cable from negative terminal of battery

   Caution

   Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (–) terminal cable is disconnected from the battery.

2. Remove drive belt

   

   1. Loosen the pivot bolt and adjusting lock bolt.
   2. Loosen the adjusting bolt, and disconnect the drive belt from the alternator.

3. Remove alternator

   

   1. Disconnect the alternator connector.
   2. Remove the nut, and disconnect the alternator wire.
   3. Remove the pivot bolt, adjusting lock bolt and alternator.

Components¶

Disassembly of alternator¶

(See Components)

1. Remove rear end cover

   1. Remove the nut and terminal insulator.

      

   2. Remove the three nuts and end cover.

      

2. Remove brush holder and IC regulator

   1. (80 A and 100 A Types)

      Remove the brush holder cover from the brush holder.

      

   2. Remove the five screws, brush holder and IC regulator.

      

3. Remove rectifier holder

   1. Remove the four screws and rectifier holder.

      

   2. Remove the four rubber insulators.

      

   3. (80 A and 100 A Types)

      Remove the seal plate.

      

4. Remove pulley

   1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

      

      SST 09820-63010

      Torque: 400 kg-cm (29 ft-lb, 39 N·m)

   2. Check that SST (A) is secured to the rotor shaft.

   3. As shown in the figure, mount SST (C) in a vise, and install the alternator to SST (C).

      

   4. To loosen the pulley nut turn SST (A) in the direction shown in the figure.

      Notice

      To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.

   5. Remove the alternator from SST (C).

   6. Turn SST (B) and remove SST (A and B).
   7. Remove the pulley nut and pulley.

5. Remove rectifier end frame

   1. Remove the four nuts.

      

   2. Using SST, remove the rectifier end frame.

      

      SST 09286-46011

   3. (80 A and 100 A Types)

      Remove the alternator washer.

      

6. Remove rotor from drive end frame

   

Inspection and repair of alternator¶

Rotor¶

1. Inspect rotor for open circuit

   

   Using an ohmmeter, check that there is continuity between the slip rings.

   Standard resistance (Cold): 2.8 – 3.0 Ω

   If there is no continuity, replace the rotor.

2. Inspect rotor for ground

   

   Using an ohmmeter, check that there is no continuity between the slip ring and rotor.

   If there is continuity, replace the rotor.

3. Inspect slip rings

   

   1. Check that the slip rings are not rough or scored.

      If rough or scored, replace the rotor.

   2. Using vernier calipers, measure the slip ring diameter.

      Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.)

      Minimum diameter: 12.8 mm (0.504 in.)

      If the diameter is less than minimum, replace the rotor.

Stator (drive end frame)¶

1. Inspect stator for open circuit

   

   Using an ohmmeter, check that there is continuity between the coil leads.

   If there is no continuity, replace the drive end frame assembly.

2. Inspect stator for ground

   

   Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame.

   If there is continuity, replace the drive end frame assembly.

Brushes¶

1. Inspect exposed brush length

   

   

   Using scale or vernier calipers, measure the exposed brush length.

   Standard exposed length: 10.5 mm (0.413 in.)

   Minimum exposed length: 1.5 mm (0.059 in.)

   If the exposed length is less than minimum, replace the brushes (70 A type) or brushes and brush holder assembly (80 A and 100 A types).

2. (70 A type) If necessary, replace brushes

   1. Unsolder and remove the brush and spring.

      

   2. Run the wire of a new brush through the hole in the brush holder, and insert the spring and brush into the brush holder.

   3. Solder the brush wire to the brush holder at specified exposed length.

      

      Exposed length: 10.5 mm (0.413 in.)

   4. Check that the brush moves smoothly in the brush holder.

   5. Cut off the excess wire.
   6. Apply insulation paint to the soldered point.

Rectifiers (rectifier holder)¶

1. Inspect positive rectifier

   

   1. Using an ohmmeter, connect one test probe to the positive (+) terminal and the other to each rectifier terminal.
   2. Reverse the polarity of the tester and repeat (a).

   3. Check that one shows continuity and the other shows no continuity.

      If continuity is not as specified, replace the rectifier holder.

2. Inspect negative rectifier

   

   1. Using an ohmmeter, connect one test probe to each negative (–) terminal and the other to each rectifier terminal.
   2. Reverse the polarity of the tester probes and repeat (a).

   3. Check that one shows continuity and the other shows no continuity.

      If continuity is not as specified, replace the rectifier holder.

Bearings¶

1. Inspect front bearing

   

   Check that the bearing is not rough or worn.

2. If necessary, replace front bearing

   1. Remove the four screws, bearing retainer and bearing.

      

   2. Using socket wrench and press, press out the bearing.

      

   3. Using SST and a press, press in a new bearing.

      

      SST 09608-20012 (09608-00030)

   4. Install the bearing retainer with the four screws.

3. Inspect rear bearing

   

   Check that the bearing is not rough or worn.

4. If necessary, replace rear bearing

   1. Using SST, remove the bearing cover and bearing.

      

      SST 09820-00021

      Notice

      Be careful not to damage the fan.

   2. Using SST and a press, press in a new bearing and bearing cover.

      

      SST 09285-76010

Assembly of alternator¶

(See Components)

1. Install rotor to rectifier end frame

   

   1. Place the rectifier end frame on the pulley.
   2. Install the rotor to the rectifier end frame.

2. Install rectifier end frame

   1. (80 A and 100 A Types)

      Place the alternator washer on the rotor.

      

   2. Using a plastic-faced hammer, lightly tap in the rectifier end frame.

      

   3. Install the four nuts.

      

3. Install pulley

   

   1. Install the pulley to the rotor shaft by tightening the pulley nut by hand.

   2. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.

      SST 09820-63010

      Torque: 400 kg-cm (29 ft-lb, 39 N·m)

   3. Check that SST (A) is secured to the pulley shaft.

   4. As shown in the figure, mount SST (C) in a vise, and install the alternator to SST (C).

      

   5. To torque the pulley nut turn SST (A) in the direction shown in the figure.

      Torque: 1,125 kg-cm (81 ft-lb, 110 N·m)

   6. Remove the alternator from SST (C).

   7. Turn SST (B) and remove SST (A and B).

4. Install rectifier holder

   1. (80 A and 100 A Types)

      Place the seal plate on the rectifier end frame.

      

   2. Install the four rubber insulators on the lead wires.

      

   3. Install the rectifier holder with the four screws.

      

5. Install IC regulator and brush holder

   (70 A Type)

   1. Install the brush holder cover to the brush holder.

      

      Notice

      Be careful about the holder installation direction.

   2. Place the IC regulator together with the brush holder horizontally on the rectifier end frame.

   3. Install the five screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector.

      

   4. Fit the brush holder cover.

      

   (80 A and 100 A Types)

   1. Place the IC regulator together and brush holder on the rectifier end frame.

      

      Notice

      Be careful about the holder installation direction.

   2. Install the five screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector.

   3. Place the brush holder cover on the brush holder.

      

6. Install rear end cover

   1. Install the end cover with the three nuts.

      

   2. Install the terminal insulator with the nut.

      

7. Check that rotor rotates smoothly

   

Installation of alternator¶

1. Install alternator

   

   1. Mount the alternator on the alternator brackets with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet.
   2. Connect the alternator connector.
   3. Connect the alternator wire with the nut.

2. Install drive belt

   

   Adjust the drive belt tension. (See On-vehicle inspection, step 3)

   Drive belt tension:

   • New belt 120 ± 20 lb
   • Used belt 104 ± 20 lb

3. Connect cable to negative terminal of battery

4. Perform on-vehicle inspection (See On-vehicle inspection, steps 5–7)