Alternator Repair Procedures

Removal

1. 1
   Disconnect the negative battery cable.
2. 2
   Loosen the mounting bolts (A), then turn the adjusting bolt (B) clockwise to release the belt tension.

   

3. 3
   Remove the drive belt (A).

   

4. 4
   Disconnect the air compressor connector (A) and the generator connector (B), and disconnect the cable from the generator "B" terminal (C).

   

5. 5
   Remove the alternator (A).

   

Installation

1. 1
   Install in the reverse order of removal.
2. 2
   After installation, adjust the alternator belt tension. (Refer to Engine Mechanical System - "Drive Belt") Alternator mounting bolt: [12 mm (0.47 in) bolt] 19.6 ~ 26 N·m [14 mm (0.55 in) bolt] 29.4 ~ 41 N·m

Disassembly

1. 1
   Remove the rear cover (A) after removing the nuts.

   

2. 2
   Remove the mounting bolts (A) and the brush holder assembly (B).

   

3. 3
   Remove the slip ring guide (A) by pulling it.

   

4. 4
   Remove the OAD (Overrunning Alternator Decoupler) cover.
5. 5
   Remove the OAD pulley (overrunning alternator decoupler) (A) using the special service tool.

   

6. 6
   Unsolder the 3 stator wires (A).

   

7. 7
   Remove the 4 through bolts (A).

   

8. 8
   Separate the rotor (A) and the bracket (B).

   

Installation

1. Assemble in the reverse order of disassembly.

Inspection

[Rotor]

1. 1
   Check that there is continuity between the slip rings (C).

   

2. 2
   Make sure there is no continuity between the slip rings and the rotor (B) or the rotor shaft (A).
3. 3
   If the rotor fails the continuity check, replace the generator.

[Stator]

1. 1
   Check for continuity between each pair of wires (A).

   

2. 2
   Make sure there is no continuity between each terminal and the coil core.
3. 3
   If the coil fails the continuity check, replace the generator.