Remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.
3.
Heat Shield - Remove
4.
Terminal Insulator - Remove
5.
End Cover - Remove
6.
Brush Holder Assembly - Remove
7.
Stator Assembly - Remove
8.
Rotor - Remove
9.
Front Bearing Retainer - Remove
10.
Front Bearing - Remove
1.
Drive out the front bearing with a brass drift and a hammer.
Brush Holder
1.
Brush - Inspect
1.
Measure the length of both brushes (A) with a vernier caliper (B). If either brush is shorter than the service limit, replace the brush holder assembly.
Alternator Brush Length
Standard (New):
10.5 mm (0.413 in)
Service Limit:
1.5 mm (0.059 in)
Rotor
1.
Rotor Slip Ring - Test
1.
Check for continuity between the slip rings (A):
If there is continuity, go to step 2.
If there is no continuity, replace the rotor assembly.
2.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
If there is continuity, replace the rotor assembly.
NOTE: Where icon is shown, click for further information.
1
Detailed information, notes, and precautions
Torque: N·m (kgf·m, lbf·ft)
Replace
*1
These parts have inspection items.
1.
Front Bearing - Install
1.
Use a hand press to install the front bearing (A) in the drive-end housing, with the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.
2.
Front Bearing Retainer - Install
3.
Rotor - Install
4.
Stator Assembly - Install
5.
Brush Holder Assembly - Install
1.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.
2.
Install the brush holder assembly.
3.
Pull out the pin or drill bit.
6.
End Cover - Install
7.
Terminal Insulator - Install
8.
Heat Shield - Install
9.
Pulley - Install (Without OAD)
1.
Tighten the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B).
