Alternator - Assemble
- If removed, press bearing (24) into rear housing. Then, install seal (23) and snap ring (22) .
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| Illustration 1 | g01066822 |
- Using a pair of long nose pliers as a heat sink, solder stator leads (20) to the correct terminals (as marked at disassembly) of the diode assemblies (21) with rosin core solder.
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| Illustration 2 | g01066824 |
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| NOTICE |
|---|
Failure to use long nose pliers as a heat sink can cause damage to the diodes because of too much heat during lead soldering. |
- Install insulated washers and plastic sleeves onto the diode assembly mounting bolts prior to installation into rear housing.
- Install diode assemblies into rear housing.
- Install washers (19) and nuts (18) to hold diode assemblies in rear housing. Refer to Specifications, "Alternator" for torque requirements.
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| Illustration 3 | g01066814 |
- Connect three wires (marked at disassembly) to the diode assemblies with two bolts (17). Tighten the bolts to a torque of 2.8 N·m (25 lb in).
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| Illustration 4 | g01066803 |
- Position stator into rear housing and install three nuts (16) to attach stator winding leads. Tighten the nuts to a torque of 4 N·m (35 lb in).
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| Illustration 5 | g01059946 |
- If removed, install bearing retainer (14) and felt seal (15) onto rotor assembly shaft. Then, press front bearing (13) onto rotor assembly shaft.
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| Illustration 6 | g01059928 |
- If removed, install seal into front housing.
- Install front housing onto rotor assembly. If necessary, use a hydraulic press. Install three bolts (12) in front housing. Tighten the bolts to a torque of 3.4 N·m (30 lb in).
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| Illustration 7 | g01059919 |
- Install front housing and rotor assembly (10) into rear housing and stator assembly (11). Align the housing marks made at disassembly. Install the four housing bolts (9) and tighten to a torque of 5 N·m (45 lb in).
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| Illustration 8 | g01059884 |
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| Illustration 9 | g01059882 |
- Position the brush assembly (8) into the cavity and install the two bolts (7). Tighten the bolts to a torque of 2.8 N·m (25 lb in). Connect the two wires (6) to the correct brush assembly terminals as marked at disassembly.
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| Illustration 10 | g01066265 |
- Position the brush assembly gasket and cover (5) on the back of the alternator. Install the two bolts (4) and tighten to a torque of 2.8 N·m (25 lb in).
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| Illustration 11 | g01059874 |
- Connect the regulator wires to the correct terminals as marked at disassembly. Tighten nuts to a torque of 2.3 N·m (20 lb in).
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| Illustration 12 | g01058887 |
- Install the regulator and the four screws (3). Tighten the screws to a torque of 5 N·m (45 lb in).
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| Illustration 13 | g01058878 |
- Install the rear debris cover (2) on the back of the alternator and install the 3 screws (1). Tighten the screws to a torque of 4.5 N·m (40 lb in).
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| Illustration 14 | g01058854 |
- Install the spacer, key, fan, pulley, washer and pulley nut. Tighten the pulley nut to a torque of 102 N·m (75 lb ft).
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