Charging

1. Alternator assembly
   1. Pulley lock nut
   2. Alternator pulley
   3. Spacer
   4. Drive end frame assembly
   5. Stud bolt
   6. Bearing
   7. Retainer plate
   8. Alternator rotor assembly
   9. Spacer
   10. Bearing
   11. Bearing cover
   12. Rectifier end frame assembly
   13. Nut
   14. Rectifier holder
   15. Regulator assembly
   16. Brush
   17. Spring
   18. Brush holder
   19. Rear end cover

CH00004-00000

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1. Prior to the inspection, make sure that the battery cables are connected securely.
2. When a quick charging operation is carried out, first be sure to disconnect the battery cables.
3. Never use a high-voltage insulation resistance tester for the purpose of conducting this inspection.
4. Under no circumstances should the battery cables be disconnected while the engine is rotating.

• Box wrench, 8 × 10 mm
• Box wrench, 10 × 12 mm
• Box wrench, 12 × 14 mm
• Philips screwdriver, 200 mm
• Nose pliers
• Socket wrench, 22 mm
• Air impact wrench
• Adjustable wrench, 300 mm
• Torque wrench
• Circuit tester
• Vernier calipers, 150 mm
• SSTs
  • 09820-06010-000
  • 09820-06020-000

1. Prior to the in-vehicle inspection, be sure to perform the following checks.
   1. Specific gravity of battery electrolyte
   2. Installation of battery terminals
   3. Tension of V-belt
   4. Fuse
   5. Wiring harness
   6. Abnormal noise emitted from alternator while engine is rotating
2. Output test under unloaded state
   1. Ensure that all switches are turned OFF so that no unnecessary electric load may be applied.
      • Headlamps
      • Heater blower
      • Radio
      • Rear defogger
      • Room lamp, etc.
   2. Raise the engine revolution speed gradually to 2500 грm.
      Measure the current and voltage at 2500 rpm.
      Specifications:
      • 10 A or more
      • 14.2 - 14.8 V
   3. NOTE:
      • Immediately after the engine starting, the current may jump to 10 A or more momentarily. This is not an abnormal phenomenon.
      • If the voltage reading i s less than the standard voltage, ground the terminal F as indicated in the right figure. Proceed to start the engine.
      • If the voltage reading becomes greater than the standard voltage under this setting, replace the IC regulator.
      • If the voltage reading is still less than the standard voltage under this setting, check the alternator.
3. Output test under loaded state
   1. To apply electric load, perform the following operation.
      1. Set the headlamps to the upper-beam position.
      2. Set the heater blower to the “High” position.
   2. Measure the output current of the alternator at the engine speed of 2500 rpm.
      • Specified Value: 20 A or more
   3. NOTE:
      • When the battery is fully charged, the measured current may be below the specified value. This is not an abnormal phenomenon.
      • At this time, increase the electric load, for example, by turning ON the rear defogger.
      • Then, check to see if the output current rises or not.

1. Disconnect the negative (−) terminal of the battery.
   • This is the 8 mm nut on top of the alternator
2. Remove the couplers for the B, IG and L terminals of the alternator.
   • This is the connector on the back of the alternator
   • The clip to depress is on the side of the connector facing the rear of the car
3. Remove the alternator attaching bolts
4. Remove the V-belt

The above service manual procedure has been modified below to be easier for a single person to execute.

Legend:

• ⬆️ Access from the engine bay
• ↘️ Access from the right-hand wheel well below the car

1. ⬆️ Disconnect the negative (−) terminal of the battery
   • Remove the 8 mm hex nut
   • Disconnect the ring terminal
   • Reinstall the 8 mm hex nut for safekeeping
2. ⬆️ Disconnect the connector on the back of the alternator (B, IG and L connection)
3. ↘️ Jack up the front left jack point of the car
   • Ensure the handbrake is engaged so as to prevent the car from rolling
   • Secure the car with a jack stand
4. Turn the steering fully to the left (counter-clockwise)
5. ↘️ Loosen slightly (1-2 rounds CCW) the lower bolt (14 mm) of the alternator but do not fully remove it
6. ⬆️ Remove the upper bolt (12 mm) of the alternator
7. ⬆️ Rotate the alternator towards the front of the engine to loosen the V-belt
8. ⬆️ Remove the V-belt from the alternator pulley and loosely hang it on the remaining pulleys
9. ↘️ Hold on to the alternator with one hand, and remove the lower bolt fully. Rest the alternator on the engine sub-frame
10. ↘️ Remove the alternator by rotating it and squeezing it between the steering rack end and front axle

1. Inspection of rotor for open circuit.
   1. Using an ohmmeter, check to see if specified resistance exists between the rotor slip rings.
      • Standard resistance: 2.9 ± 0.2 Ω
   2. If no specified resistance exists, replace the rotor.
2. Inspection of rotor for ground
   1. Ensure that no continuity exists between the rotor slip rings and the rotor core.
   2. If no continuity exists, replace the rotor.
3. Inspection of slip rings
   1. Check to see if the slip ring surface exhibits roughness, abnormal wear and/or burning.
      Replace the rotor, if necessary.
   2. Measure the outer diameter of the slip ring, using vernier calipers.
      • Standard Diameter: 14.4 mm (0.567 inch.)
      • Minimum Diameter: 14 mm (0.551 inch.)
   3. If the slip ring diameter is less than the minimum diameter, replace the rotor assembly.

1. Inspection of stator for open circuit
   1. Using an ohmmeter, check to see if any open circuit of the stator coil is present between the leads.
   2. If no continuity exists, replace the end frame assembly.
      • Specified Resistance: About 0.2 Ω
2. Inspection of stator for short circuit
   1. Using an ohmmeter, check to see if any short circuit of the stator coil is present between the coil lead and the drive end frame.
   2. If continuity exists, replace the drive end frame assembly.

1. Measurement of exposed brush length
2. Measure the exposed brush length, using a scale.
   • Standard Exposed Length: 10.5mm (0.413 inch.)
   • Minimum Exposed Length: 1.5 mm (0.059 inch.)
3. If the exposed length is less than the minimum required, replace the brushes.

1. Measurement of exposed brush length
   1. Measure the exposed brush length, using a scale.
      • Standard Exposed Length: 10.5mm (0.413 inch.)
      • Minimum Exposed Length: 1.5 mm (0.059 inch.)
2. If the exposed length is less than the minimum required, replace the brushes.
3. Replacement of brushes (If necessary)
   1. Remove the brush and spring from the brush holder by melting the solder by means of a soldering iron.
      • NOTE:
        • Prior to the operation, remove the painting film at the solder surface with a knife or the like.
        • For this operation, it is advisable to use a soldering iron with a capacity of about 40W.
   2. Install the brush cord in the brush holder with the spring fitted in place.
      • NOTE:
        • Using a knife, etc., remove the soldered section of the brush holder to form a flat surface until the bare metal is exposed.
   3. Solder the brush cord in the brush holder in such a way that the exposed length of the brush meets the specifications.
      • Standard Exposed Length: 10.5 mm (0.413 inch.)
      • NOTE:
        • Prior to the operation, let solder flow onto the forward end of the brush wire.
        • To facilitate soldering:
          • Route the wire through the holder hole and adjust the exposed length of the brush t o the specification.
          • Bend the wire at its forward end on which solder has been applied in the preceding step. Then, solder the wire to the holder.
   4. Ensure that the brush moves freely in the brush holder.
   5. Cut off any excess remaining wire and apply an insulation paint.

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1. Temporarily install the alternator on the engine with the two attaching bolts.
2. Install the alternator drive belt properly.
3. Adjust the belt tension in such a way that the deflection of the drive belt meets the specification when you push the midpoint of the drive belt between the alternator pulley and the water pump pulley by applying a force of 98 N (10 kgf).
   • Specified Belt Deflection:
     • New belt: 5.0 - 7.0 mm
     • Used belt: 6.0 - 8.0 mm
   • NOTE:
     • The new belt refers to a belt which has been used less than five minutes on a running engine.
4. Install the B wire and connector to the alternator.
5. Reconnect the ground cable terminal to the negative (−) terminal of the battery.