Removing the generator assembly.
1 - adjusting bolt, 2 - alternator, 3 - pivot bolt, 4 - alternator adjusting plate.
Generator.
1 - hex nut, 2 - pulley, 3 - spacer, 4 - screw, 5 - rotor assembly, 6 - alternator rear bearing, 7 - bearing retainer, 8 - alternator front bearing, 9 - alternator front bracket, 10 - stator assembly, 11 - alternator rear bracket, 12 - bolt, 13 - rectifier assembly, 14 - regulator assembly, 15 - alternator cover, 16 - nut, 17 - outlet insulating cap "IN"
Withdrawal
1. Disconnect a wire from the negative plug of the storage battery.
2. Disconnect the radiator fan connector and the A/C condenser fan connector.
3. Turn away bolts of fastening of support of a radiator.
4. Loosen the adjusting bolt on the alternator adjusting bar and remove the retaining bolt. Then raise the car.
5. Disconnect the generator connector and disconnect the wire from the output "IN" generator.
6. Remove the alternator drive belt. Turn away a nut and a bolt of hinged fastening of the generator.
7. Raise the radiator and remove the generator assembly.
Installation
1. Put the alternator in place and insert the pivot bolt. (Do not overtighten the pivot bolt nut.)
2. Push the alternator forward and determine how many spacers (each 0.198 mm thick) must be inserted between the front strut of the generator and the front cover of the engine (gap "A" on the image).
Note: Choose enough spacers so that they don't fall off when you try to fit them into the gap.
3. Insert spacers (gap "A" on the image), connect and tighten the pivot bolt nut.
4. After installation is complete, adjust the alternator drive belt tension.
Disassembly
1. Loosen the four pinch bolts.
2. Insert a flathead screwdriver between the alternator front bracket and the stator and use the screwdriver as a lever to pry the (down) generator front bracket.
Note:
- Do not insert the screwdriver too far to avoid damaging the stator winding.
- It may be difficult to remove the alternator rear bracket because the circlip used to secure the rear bearing is in the way. To facilitate rear bracket removal, heat the bearing assembly with a 200 watt soldering iron. Do not use a heat gun for heating, as this may damage the rectifier diodes.
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
3. Clamp the rotor in a soft jaw vise with the pulley side up.
Caution: Be careful not to damage the rotor with the vise jaws.
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
4. Loosen the pulley nut, remove the spring washer, then remove the pulley and spacer.
5. Remove the alternator front bracket and two o-rings.
6. Remove the rotor from the vise.
7. Turn away screws of fastening of a brush holder and the straightening block. Then unscrew the output nut "IN" generator.
8. Remove the stator assembly from the alternator rear bracket.
9. Remove the dust ring from the brush holder.
10. Before removing the stator, unsolder the three stator winding wires from the main rectifier diodes.
Note:
- When soldering/desoldering contacts, be careful that the heat from the soldering iron affects the diodes as little as possible. Perform these operations as quickly as possible.
- Be careful not to apply excessive force to the diode pins.
11. Before disconnecting the rectifier unit from the brush holder, unsolder the two pins soldered to the rectifier unit.
Examination
Rotor
1. Check for an open in the rotor winding.
Check for continuity between the slip rings. If there is too little resistance (tends to 0), it means there is a short circuit. In the event of an open circuit in the rotor winding or a short circuit, replace the rotor assembly.
- Resistance Approx: 3.1 ohm
2. Check that the rotor winding is not shorted to "mass". Check for continuity between slip ring and core. If there is a closed circuit (short circuit "mass") replace the rotor assembly.
Stator
1. Check for an open in the stator winding. Check for continuity between the stator winding terminals. If the winding circuit is open (resistance tends to infinity), then replace the stator assembly.
2. Check the absence of a short circuit in the stator winding on "mass" (those. lack of a closed circuit between the stator winding and the core). If the circuit is closed (resistance tends to zero), then replace the stator assembly.
Checking the positive output of the rectifier unit
1. Using an ohmmeter, check that the circuit between the positive" diodes of the rectifier unit and the output of the stator winding is closed (little resistance).
2. Reverse the polarity of the ohmmeter probes and measure the resistance (if the resistance is small, i.e. the circuit is closed in both directions, then the diode "broken"). Replace the rectifier assembly.
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
Checking the negative terminal of the rectifier unit
1. Using an ohmmeter, check that the circuit between the terminal "negative" diodes of the rectifier unit and the output of the stator winding is closed (little resistance).
2. Reverse the polarity of the ohmmeter probes and measure the resistance (if there is little resistance. those. the circuit is closed in both directions, then the diode "broken"). Replace the rectifier assembly.
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
Checking the three diodes of the rectifier unit
1. Test three diodes by connecting an ohmmeter to both terminals of each diode. For each diode, the circuit must be closed in only one direction.
2. No closed circuit in both directions (or if there is a closed circuit in both directions) the diode is faulty and the rectifier unit (together with a cooling radiator) to be replaced.
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
Brush replacement
1. Measure the length of the protruding part of the brush shown in the figure, and replace the brushes if the measured value is less than the limit value.
- Limit value: 2 mm or less
Engines 2.0 l / 2.4 l. | Engine 2.7 l. |
2. If you need to remove the brush, unsolder the brush wire from the brush holder.
3. When installing a new brush, insert it into the brush holder and solder the brush wire.
Assembly
Assembly is carried out in the reverse order of disassembly.
When performing assembly operations, pay attention to the following:
Before installing the rotor in the rear bracket, insert a thin wire into the small hole in the rear bracket to secure the raised brushes. The wire should be removed after installing the rotor.