Remove
Alternator see operation "Alternator Remove and Install".
Caution
When cleaning all components electric windings may only briefly come into contact with cleaning agents.
Disassemble
Cable from rear cover – rubber cap and nut; clip.
Vacuum pump from rear cover – three bolts.
Disassemble
Through bolts (arrowed) - mark position of front and rear housings relative to stator.
Disassemble
Front housing with armature from stator and rear housing – use screwdriver to carefully separate.
Disassemble
Nuts (arrowed) that secure stator to rear housing.
Disassemble
Stator with diode plate and brush holder from bear housing – use screwdriver to carefully lever out.
Disassemble
Pulley nut from armature – use soft-jawed vice.
Disassemble
Pulley fan spacer and front housing from armature.
Disassemble
Bearing from armature – use puller.
Disassemble
Bearing retainer from front housing – screws (arrowed).
Disassemble
Bearing from front housing - press out manually or drive out with suitable drift.
Disassemble
Seal from rear housing - use screwdriver.
Disassemble
Stator leads from diode plate – unsolder connections (arrowed).
Caution
Hold wire to diode with long-nose pliers to prevent overheating of diode.
Disassemble
Brush holder from diode plate - insulating sleeve and bolt (1) and unsolder connection (arrowed).
Disassemble
Regulator from brush holder – unsolder connections.
Alternator Components Check
Inspect
Check there is no continuity between each phase winding and stator core – use ohmmeter.
Replace stator if continuity is found.
Measure
Measure resistance between connection wire of each phase winding - use ohmmeter.
If resistance is not approx. 0.1 ohm replace stator.
Inspect
Check there is no continuity between slip ring and armature core – use ohmmeter.
Measure
Measure resistance between slip rings.
Replace armature if resistance is not 4.2 ohms at 20 °C.
Measure
Diameter of slip rings.
Replace armature if diameter is less than 30.6 mm.
Inspect
Slip rings for wear.
Clean and polish slip rings - use fine emery cloth (P500 to 600).
Recut surface of slip rings if necessary. Minimum diameter A 30.6 mm.
Polish slip rings and remove swarf after cutting.
Inspect
Diodes – faults can be detected from presence of peaks or troughs in voltage wave on oscilloscope.
Diode can be checked on removed diode plate – use diode tester ohmmeter or test circuit with lamp.
If diode is faulty replace diode plate.
Caution
Test voltage must not exceed 24 V.
Inspect
Negative diodes (A) individually.
Positive probe (B) to diode plate negative probe (C) to diode connection – diode should have continuity.
Reverse probe connections – diode should have no continuity.
Inspect
Positive diodes (A) individually.
Positive probe (B) to diode connection negative probe (C) to diode plate – diode should have continuity.
Reverse probe connections – diode should have not continuity.
Inspect
Excitation diodes (A) individually.
Positive probe (B) to long wire negative probe (C) to short wire – diode should have continuity.
Reverse probe connections – diode should have no continuity.
Measure
Carbon brush length A.
If length is less than 6 mm replace brushes.
Brushes are marked with a line that indicates limit of usage.
Alternator Assemble
Assemble
Bearing (1) to armature - twist protection if provided must face away from slip rings.
Assemble
Bearing and bearing retainer to front housing - screw (arrowed).
Assemble
Regulator to brush holder - solder connections.
Assemble
Brush holder to diode plate – solder connection (arrowed).
Insulating sleeve (1) on bolt.
Assemble
Stator leads to diode plate – solder connections (arrowed).
Caution
Hold wire to diode with long-nose pliers to prevent overheating of diode.
Assemble
Front housing spacer fan pulley and nut to armature – use soft-jawed vice to hold armature; nut 50 Nm.
Assemble
New seal to rear housing.
Stator with diode plate and brush holder to rear housing - align marks made during disassembling tighten nuts (arrowed).
Wrap insulation tape around splindes on armature.
Lift brush (1) from outside through aperture in rear housing – use pin (2) to retain brush.
Assemble
Front housing with armature to rear housing – align marks made during disassembling - through bolts 6 Nm.
Remove insulation tape from splines and pin from brush.
Assemble
Insulating sleeve (arrowed) to terminal B.
Cable to terminal B – nut and rubber cap; clip.
Assemble
Vacuum pump to rear housing – pour 5 ml. of engine oil into filler port – three screws 7 Nm.
Inspect
Check pulley can be turned easily by hand.
Check alternator output – see operation "Alternator Output Check".