Voltage Regulator and Alternator Brush Replacement

This section describes the procedure for measuring the brushes and voltage regulator on Nippondenso alternators fitted to 4-cylinder models. On V6 models, the regulator is replaced together with the Mitsubishi/Delphi alternator.

Remove the alternator from the vehicle (refer to Alternator Removal and Installation) and place it on the workbench.
Brushes
PROCEDURE

1. Remove the three retaining nuts and remove the alternator rear cover. Also remove the retaining nut and remove the terminal insulator.

2. Remove the two brush holder retaining screws.

3. Remove the brush holder from the rear end of the alternator.

4. Measure the protrusion of each brush from its holder bore and compare the results with the Specifications. If the brush protrusion is below the lower limit of the allowable range, replace the brushes.

5. Check that the brushes move freely in the holder bores.
6. When installing the brush holder, push the brushes back with a small screwdriver to allow the shaft to pass.
7. Install and tighten the retaining screws.
8. Install the rear cover and firmly tighten the three retaining nuts.
9. Install the terminal insulator and tighten its retaining nut.
10. Install the alternator in its original position (refer to Alternator Removal and Installation).

Voltage Regulator
PROCEDURE

1. Perform the procedures described above in steps 1 through 3. Remove the screws securing the regulator to the alternator rear frame assembly.

2. Remove the regulator from the alternator assembly.
3. Install in the reverse order of removal.