Alternator: Service and Repair
GENERATOR ASSEMBLYREMOVAL AND INSTALLATION [2.4L ENGINE]
Pre-removal & Post-installation Operation:
Removal Steps 1-7:
REMOVAL SERVICE POINTS
[[A]] A/C COMPRESSOR ASSEMBLY REMOVAL
1. Remove the A/C compressor assembly from the A/C compressor bracket with the hose still attached.
2. Place the removed A/C compressor assembly where it will not be a hindrance when removing and installing the generator assembly, and secure it with a cord or wire.
[[B]] GENERATOR ASSEMBLY REMOVAL
Move the A/C compressor assembly to one side, and then remove the generator assembly from under the vehicle.
INSTALLATION SERVICE POINTS
]]A[[ GROUNDING CABLE INSTALLATION
Install the grounding cable within the area marked with A in the illustration.
]]B[[ A/C COMPRESSOR ASSEMBLY INSTALLATION
1. Temporarily tighten the A/C compressor assembly to the A/C compressor bracket.
2. In accordance with the tightening order shown in the illustration, tighten the installation bolts for the A/C compressor bracket to the specified torque.
Tightening torque: 23 ± 6 Nm (17 ± 4 ft-lb)
REMOVAL AND INSTALLATION [3.0L ENGINE]
Pre-removal & Post-installation Operation:
Removal Steps 1-10:
REMOVAL SERVICE POINTS
[[A]] GENERATOR DRIVE BELT REMOVAL
CAUTION: When the generator drive belt is reused, draw an arrow indicating the rotating direction on the back of the belt using chalk to install the same direction.
1. Turn the drive belt auto-tensioner to counterclockwise, and insert the L-shaped hexagon wrench to the auto-tensioner hole in order to fix the auto-tensioner.
2. Remove the generator drive belt.
[[B]] A/C COMPRESSOR ASSEMBLY REMOVAL
1. Remove the A/C compressor assembly from the A/C compressor bracket with the hose still attached.
2. Place the removed A/C compressor assembly where it will not be a hindrance when removing and installing the generator assembly, and secure it with a cord or wire.
[[C]] GENERATOR ASSEMBLY REMOVAL
Move the A/C compressor assembly to one side, and then remove the generator assembly from under the vehicle.
INSTALLATION SERVICE POINT
]]A[[ GENERATOR ASSEMBLY INSTALLATION
1. Temporarily tighten the generator assembly to the generator bracket.
2. In accordance with the tightening order shown in the illustration, tighten the installation bolts for the generator bracket to the specified torque.
Tightening torque: 47 ± 11 Nm (35 ± 8 ft-lb)
DISASSEMBLY AND REASSEMBLY
[2.4L ENGINE]
Disassembly Steps 1-15:
[3.0L ENGINE]
Disassembly Steps 1-14:
DISASSEMBLY SERVICE POINTS
[[A]] PULLEY REMOVAL [2.4L ENGINE]
1. Set the special tool Serration socket (MB992226) to the pulley.
2. Set the closed wrench to the hexagonal area of the special tool Serration socket (MB992226).
3. Insert the hexagonal bit socket having width across flats of 10 mm into the hexagonal area of the rotor shaft.
4. Hold the pulley with the closed wrench. Rotate the rotor shaft clockwise to remove the pulley.
[[B]] FRONT BRACKET REMOVAL[2.4L ENGINE]
CAUTION: Do not insert the screwdriver blades too deep. Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front bracket and stator core, and pry and separate them with the screwdrivers.
[[C]] FRONT BRACKET ASSEMBLY REMOVAL[3.0L ENGINE]
CAUTION: Do not insert the screwdriver blades too deep. Doing so could damage the stator coil.
Insert the blades of screwdrivers between the front bracket assembly and stator core, and pry and separate them with the screwdrivers.
[[D]] ALTERNATOR PULLEY REMOVAL[3.0L ENGINE]
CAUTION: Perform operation carefully not to damage the rotor. Clamp the rotor in a vise with the pulley facing up to remove the pulley.
[[E]] STATOR / REGULATOR ASSEMBLY REMOVAL
CAUTION:
^ Use a 180 - 250 W soldering iron, and finish unsoldering within four seconds. Diodes will be damaged by heat if unsoldering time is too long.
^ Avoid applying undue force to the diode leads.
1. Unsolder the stator leads from the main diode of the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the regulator assembly, undo the soldered points on the rectifier assembly.
REASSEMBLY SERVICE POINTS
]]A[[ REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a piece of wire through the hole in the rear bracket while pressing the brush to keep the brush against movement.
NOTE: Holding the brush with the wire facilities installation of the rotor
]]B[[ ROTOR INSTALLATION
Remove the brush holding wire after the rotor has been installed.
]]C[[ PULLEY INSTALLATION [2.4L ENGINE]
1. Clean the inner race of the front bearing and that of the pulley.
2. Screws the inner race of the pulley until it touches the inner race of the front bearing.
3. Set the special tool Serration socket (MB992226) to the pulley.
4. Set the closed wrench to the hexagonal area of the special tool Serration socket (MB992226).
5. Insert the hexagonal bit socket having width across flats of 10 mm into the hexagonal area of the rotor shaft.
6. Hold the pulley with the closed wrench.
Rotate the hexagonal bit socket counterclockwise to tighten it to the specified torque of 73 ± 12 Nm (54 ± 9 ft-lb).
INSPECTION
PULLEY [2.4L ENGINE]
Lock the pulley when rotating it clockwise. Check that the pulley rotates smoothly when rotating it counterclockwise.
CAUTION: Locking the one-way clutch might cause the damaged drive belt and an abnormal noise.
ROTOR
1. Measure the resistance between the two slip rings of the rotor coil to check the continuity between them.
Replace the rotor if the resistance is not within the standard value range.
Standard value: 2.1 -2.4 ohms
2. Check the continuity between the slip rings and core.
3. If continuity is present, replace the rotor.
STATOR
1. Check the continuity between coil leads.
If there is no continuity, replace the stator.
2. Check the continuity between coil and core.
If there is continuity, replace the stator.
RECTIFIER ASSEMBLY
1. Check the condition of the (+) heat sink by checking the continuity between the (+) heat sink and each of the stator coil lead connecting terminals.
If the continuity is present for both terminals, or if no continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
2. Check the condition of the heat sink by checking the continuity between the heat sink and each of the stator coil lead connecting terminals.
If the continuity is present for both terminals, or if no continuity is present for both terminals, the diode is shorted. Replace the rectifier assembly.
BRUSH
1. Measure the length of the protrusion of the brush. Replace the brush if the protrusion length is shorter than the limit.
Limit: 2 mm (0.08 inch) minimum
2. Unsolder the lead of the brush. The brush will come out, becoming ready for removal.
3. Install a new brush by pushing it into the holder as shown in the drawing and soldering the lead.