Remove negative battery cable.
Remove front bolts from air cleaner inlet pipe.
Loosen end clamp on inlet.
Remove top hose from resonance chamber and remove air cleaner inlet pipe.
Open B-terminal cover cap.
Disconnect the generator's L-and S-terminal connectors.
Loosen pivot bolt and tensioner mounting bolt. Do not remove.
Relieve tension on drive belt by rotating adjustment bolt.
Remove drive belt from generator pulley.
Remove tensioner mounting bolt and belt tensioner.
Remove generator pivot bolt.
Loosen bolt base of adjusting bracket and rotate the bracket up.
Lift generator from engine compartment.
Position generator on engine.
Install, but leave loose, pivot bolt.
Rotate bracket down into position on top of generator.
Place belt tensioner into position on adjustment bracket.
Install tensioner mounting bolt, leave loose.
Place drive belt on generator pulley.
Adjust belt tension by rotating adjustment bolt.
New belt : 0.23-0.31inch(6-8mm)
Old belt : 0.28-0.35inch(7-9mm)
Tighten tensioner bolt : 14-19lb·ft(19-26N·m)
Tighten pivot bolt and bracket bolt.
Tighten pivot bolt : 28-38 lb·ft(38-51N·m)
Connect generator L-and S-terminal connectors.
Install and tighten B-terminal nut.
Close B-terminal nut cover.
Install air intake inlet pipe and tighten and clamp.
Connect top hose to air intake inlet pipe.
Install front air intake inlet pipe bolts.
Connect negative battery cable.
Be sure the battery connections are not reversed. This will damage the rectifier.
Do not use high voltage teaters, such as a megger. They will damage the rectifier.
Remember that battery voltage is always applied to the alternator B-terminal.
Do not ground the L-terminal while the engine is running.
Do not start the engine while the coupler is disconnected from the L-and S-terminals.
Install the generator strap and bracket.
Install the lower bracket.
Tightening torque : 69-83 ft·lb(93-113N·m)
Tightening torque : 27-38ft·lb(37-52N·m)
Install the generator drive belt and adjust the belt deflection. Refer to Charging System.
Insert protective material in the jaws of the vise.
Remove the cap screws from front housing.
Use a 200-watt soldering iron to heat the rear of the bearing box to allow the bearing to be removed from the rear housing.
If the bearing box is not heated, the bearing cannot be pulled out because the rear bearing and rear housing fit together very tightly.
Use a flat-blade screw driver to separate the front housing from the stator.
Be careful not to lose the stopper spring that fits around the rear bearing.
Insert protective material in the jaws of the vise.
Place the rotor in vise and loosen the lock nut, then disassemble the pulley, rotor and front housing.
Replace the front bearing. Using a socket which exactly fits the outer race of the bearing, carefully push in the front bearing. Use a hand press or a vise.
Replace the rear bearing. Remove rear bearing with a bearing puller. When installing, make sure the groove on the bearing rim is the slip ring side.
Remove the B-terminal nut and the insulating bushing.
Remove the screws holding the rectifier and the brush holder.
Separate the rear bracket and stator.
Disconnect quickly. If the soldering iron is used for more than 5seconds, the rectifier may be damaged by the heat.
Use a soldering iron to remove the solder from the rectifier and the stator leads, and then remove the IC regulator.
Replace the brushes. Remove the solder from the pigtail and then remove the brush.
When connecting the brush, solder the pigtail so that the wear limit line of the brush projects 0.079-0.118 inch(2-3mm) out of the brush holder.
Measure the resistance between the slip rings with a circuit tester. If it is not within standard resistance, replace the rotor.
Standard resistance : 3.5-4.5Ω
Check for continuity between the slip ring and the core with a circuit tester. Replace the rotor if there is continuity.
If the slip ring surface is rough, smooth with a lathe or fine sandpaper.
Check for continuity between the stator coil leads with a circuit tester.
Replace the stator if there is no continuity.
Check for continuity between the stator coil leads and the core with a circuit tester.
Replace the stator if there is continuity.
Check for continuity between each diode with an ohmmeter.
If the brush are worn to or beyond the limit, replace them.
Standard : 0.85inch(21.5mm)
Minimum : 0.32inch(8.0mm)
Measure the force of the brush spring with a spring pressure gauge.
Replace the spring if necessary.
Read the spring pressure with the brush tip prejecting 0.08 inch(2mm)
Standard force : 0.71-0.96lb·ft(3.1-4.1N·m)
Minimum : 0.36-0.52lb·ft(1.60-2.4N·m)
Check for abnormal noise, looseness, insufficient lubrication, etc.
Replace the bearing(s) if there is any abnormality.
Be sure to remove wire after assembly is completed.
Assemble in the reverse order of disassembly, referring to the following points.
Before assembly, use a finger to hold the brushes in the brush holder. Pass a wire 0.08 inch, 1.6-2.0inch(2mm, 40-50mm) through the hole shown in thefigure.
Secure the brushes in position.
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