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Alternator Overhaul

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Alternator Overhaul Exploded View

DRIVE-END HOUSING

BEARING RETAINER FRONT BEARING

PULLEY LOCKNUT

PULLEY

TERMINAL INSULATOR

REAR BEARING

REAR HOUSING ASSEMBLY ROTOR

Special Tools Required Handle driver ( 07749-0010000)

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Driver attachment, 52 x 55 mm ( 07746-0010400)

NOTE: Refer to the Exploded View as needed during this procedure.

1. Test the alternator and regulator before you remove them.

2. Remove the alternator.

3. Remove the four through bolts.

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Alternator Overhaul

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4. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F).

5.

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Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. NOTE: Be careful not to damage the stator with the tip of the screwdriver.

6. Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear housing.

A

B

C

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Alternator Overhaul

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7. If you are not replacing the front bearing and/or rear bearing, go to 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut.

8. Remove the rotor using a puller as shown.

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9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks. • If either the rotor or drive-end housing is damaged, replace the alternator. • If both the rotor and the drive-end housing are OK, go to 10. 10. Remove the rear bearing using the puller as shown.

11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.

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Alternator Overhaul

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12. Remove the front bearing retainer plate.

13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift (A) and hammer.

A

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14. With a hammer and the special tools, install a new front bearing in the drive-end housing.

07749-0010000

07746-0010400

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Alternator Overhaul

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Alternator Brush Inspection

15. Measure the length of both brushes with a vernier caliper. • If either brush is shorter than the service limit, replace the rear housing assembly. • If brush length is OK, go to 16.

Standard (New): Service Limit:

Alternator Brush Length: 19.0 mm (0.75 in.) 5 mm (0.2 in.)

Rotor Slip Ring Test

16. Check that there is continuity between the slip rings (A). • If there is continuity, go to 17. • If there is no continuity, replace the rotor assembly.

B

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A

C

17. Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C). • If there is no continuity, replace the rear housing assembly, go to 18. • If there is continuity, replace the rotor assembly.

Alternator Reassembly 18. If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 111 N·m (11.3 kgf·m, 81.7 lbf·ft).

19. Remove any grease or any oil from the slip rings.

20. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold them there.

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B

A

21. Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140° F).

22. Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten the four through bolts (C) and pull out the pin (D).

C

B

A

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D

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23. After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise.

24. Install the alternator, and adjust its belt tension.

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Drive Belt Replacement

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Drive Belt Replacement 1. Loosen the lock bolt (A), mounting bolt (B) and adjusting bolt (C),then remove the drive belt (D).

A

B

C D

2. Install the drive belt in the reverse order of removal.

3. Adjust the drive belt tension

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Drive Belt Inspection and Adjustment

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Drive Belt Inspection and Adjustment Special Tools Required Belt tension gauge ( 07JGG-0010100)

Belt Tension Gauge Method Inspection 1. Attach the belt tension gauge to the belt and measure the tension. Follow the gauge manufacturer's instructions. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2.

Used Belt: New Belt:

Tension: 440-590 N (45-60 kgf, 99-130 lbf) 981-1,130 N (100-115 kgf, 220-254 lbf)

With A/C compressor:

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Drive Belt Inspection and Adjustment

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07JGG-0010100

Without A/C compressor:

07JGG-0010100

Adjustment 2. Loosen the lock bolt (A) and mounting bolt (B).

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Drive Belt Inspection and Adjustment

A 8 x 1.25 mm 24 N·m (2.4 kgf·m, 17 lbf·ft)

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C

B 10 x 1.25 mm 44 N·m (4.5kgf·m, 33 lbf·ft)

3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and mounting bolt.

4. Recheck the belt tension.

5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

Deflection Method

Inspection 1. Apply a force of 98 N (10 kgf, 22 lbf), and measure the deflection at the mid point (A) between the A/C compressor (alternator for without A/C compressor) and crankshaft pulley. If the belt is worn or damaged, replace it. If the belt needs adjustment, go to step 2. Deflection: With A/C compressor: Used Belt: 5.5-8.5 mm (0.22-0.33 in.) New Belt: 3.5-5.0 mm (0.14-0.20 in.)

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Drive Belt Inspection and Adjustment

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Without A/C compressor: Used Belt: 7.5-10.5 mm (0.30-0.41 in.) New Belt: 4.5-6.0 mm (0.18-0.24 in.)

With A/C compressor:

A

Without A/C compressor:

A

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Drive Belt Inspection and Adjustment

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Adjustment 2. Loosen the lock bolt (A) and mounting bolt (B).

A 8 x 1.25 mm 24 N·m (2.4kgf·m, 17 lbf·ft)

C

B 10 x 1.25 mm 44 N·m (4.5 kgf·m, 33 lbf·ft)

3. Turn the adjusting bolt (C) to obtain the proper belt tension, then retighten the lock bolt and mounting bolt.

4. Recheck the belt tension.

5. If you installed a new belt, run the engine for 5 minutes, then readjust the belt to the used belt specification.

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Alternator Replacement (Without ETCS)

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Alternator Replacement 1. Disconnect the battery negative cable from the battery.

2. Remove the intake manifold.

3. Disconnect the alternator connector (A), WHT wire (B) and harness clamp (C) from the alternator.

B

A

C

6 x 1.0 mm 8 N·m (0.8 kgf·m, 6 lbf·ft)

4. Remove the intake manifold

5. Remove the lock bolt (A) and mounting bolt (B), then remove the alternator.

B 10 x 1.25 mm 44 N·m (4.5 kgf·m, 33 lbf·ft)

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Alternator Replacement (Without ETCS)

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A 8 x 1.25 mm 24 N·m (2.4 kgf·m, 17 lbf·ft)

6. Install the alternator in the reverse order of removal.

7. Adjust the drive belt tension.

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Charging System Circuit Diagram

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Charging System Circuit Diagram

UNDER-HOOD FUSE/RELAY BOX BATTERY

No.1 (80A)

No.3 (50A) WHT

BAT

ELD UNIT

IG1

IGNITION SWITCH

BLK/YEL

No.16 (7.5A)

GRN/RED

YEL

YEL

UNDER-DASH FUSE/RELAY BOX

YEL

CHARGING SYSTEM INDICATOR LIGHT BULB (1.4W)

AVN UNIT

ECM/PCM WHT/BLU ECM/PCM BLK

WHT

ALTERNATOR

B

WHT/GRN

BLK/YEL

C

WHT/BLU

IG

L WHT/RED

VOLTAGE REGULATOR FR

FIELD WINDING RECTIFIER

G201

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Charging System Component Location Index (Without ETCS)

Charging System Component Location Index

CHARGING SYSTEM INDICATOR (In the gauge assembly)

UNDER-HOOD FUSE/RELAY BOX (Has built-in ELECTRICAL LOAD DETECTOR (ELD) UNIT) ELD Troubleshooting (Circuit low voltage), ELD Troubleshooting (Circuit high voltage),

BATTERY Test,

ALTERNATOR Troubleshooting, Replacement, Overhaul, DRIVE BELT Inspection, Replacement,

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Charging Circuit Troubleshooting (Without ETCS)

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Charging Circuit Troubleshooting If the charging system indicator does not come on or does not go off, or the battery is dead or low, test the following items in the order listed below: Battery Charging system indicator Alternator / regulator circuit Alternator control system

Charging System Indicator Test

1. Turn the ignition switch ON (II). Does the charging system indicator come on?

YES - Go to 2.

NO - Go to 9.

2. Start the engine. Does the charging system indicator go off?

YES - Charging system indicator circuit is OK.ď Ž

NO - Go to 3.

3. Turn the ignition switch OFF.

4. Disconnect the alternator 4P connector from the alternator.

5.

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Turn the ignition switch ON (II). Does the charging system indicator come on?

YES • Without navigation system: Turn the ignition switch OFF, and repair the short in the WHT/BLU wire. If the WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may be damaged. • With navigation system: Go to 6.

NO - Repair the alternator components.

6. Turn the ignition switch OFF.

7. Disconnect the 12P connector from the AVN unit. 8. Turn the ignition switch ON (II). Does the charging system indicator come on?

YES - Turn the ignition switch OFF, and repair the short in the WHT/BLU wire. If the WHT/BLU wire is shorted to ground, the voltage regulator in the alternator may be damaged.

NO - Check that the terminals are firmly seated at the connectors. If OK, substitute a knowngood AVN unit and recheck.

9. Connect the alternator 4P connector terminal No. 3 to body ground with a jumper wire. Turn the ignition switch ON (II).

ALTERNATOR 4P CONNECTOR

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Charging Circuit Troubleshooting (Without ETCS)

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Wire side of female terminals

L (WHT/BLU)

Does the charging system indicator come on?

YES - Go to 10.

NO - Turn the ignition switch OFF. Check for a blown No. 16 (7.5 A) fuse and a blown charging system indicator bulb. If the fuse and bulb are OK, repair the open in the YEL or BLK/YEL wire to the indicator bulb.ď Ž

10. Measure the voltage at the No. 1 terminal of the alternator 4P connector with the ignition switch ON (II).

ALTERNATOR 4P CONNECTOR

Wire side of female terminals

IG (BLK/YEL)

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Charging Circuit Troubleshooting (Without ETCS)

Is there battery voltage?

YES - Go to alternator and regulator circuit test.

NO - Repair open in the YEL or BLK/YEL wire between the alternator and the under-dash fuse/relay box.

Alternator and Regulator Circuit Test

1. Be sure the battery is sufficiently charged and in good condition.

2. Hook up the following equipment: • Ammeter, 0-400A • Voltmeter, 0-20V (accurate within 0.1 V)

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Charging Circuit Troubleshooting (Without ETCS)

3. Start the engine. Hold the engine at 3,000 rpm (min-1) with no load shift lever in Park or Neutral, until the radiator fan comes on then let it idle.

4. Raise the engine speed to 2,000 rpm (min-1) and hold it there.

5. Turn the headlights (high beam) on, and measure voltage at the alternator terminal. Is the voltage between 13.9 and 15.1V?

YES - Go to 6.

NO - Repair the alternator components.ď Ž

6. Read the voltage at 13.5V. NOTE: Adjust the voltage by turn the blower motor, rear window defogger, brake lights and etc. on. Is the voltage 60A or more?

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Charging Circuit Troubleshooting (Without ETCS)

YES - Alternator/regulator operation is OK.ď Ž

NO - Repair the alternator components.ď Ž

Alternator Control System Test

1. Check for proper operation of the Electrical Load Detecter (ELD) by checking that the Malfunction Indicator Lamp (MIL) is off and there is no Diagnostic Trouble Code (DTC) for ELD failure.

2. Disconnect the alternator 4P connector from the alternator.

3. Start the engine, and turn the headlights (high beam) ON.

4. Measure voltage between the alternator 4P connector terminal No. 2 and the positive terminal of the battery.

BATTERY

C (WHT/GRN)

ALTERNATOR 4P CONNECTOR

Wire side of female terminals

Is there 1 V or less?

YES - Go to 9.

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Charging Circuit Troubleshooting (Without ETCS)

NO - Go to 5.

5. Turn the headlight and ignition switch OFF.

6. Disconnect the negative cable from the battery.

7. Disconnect Engine Control Module (ECM) /Powertrain Control Module (PCM) connector B (24P). 8. Check for continuity between ECM/PCM connector terminal B18 and body ground.

ECM/PCM CONNECTOR B (24P)

ACGC (WHT/GRN)

Wire side of female terminals

Is there continuity?

YES - Repair short to ground in the wire between the alternator and ECM/ PCM.ď Ž NO - Check that the terminals are firmly seated at the connectors. If OK, substitute a knowngood ECM/PCM, and recheck. If prescribed voltage is now available, replace the original ECM/ PCM.ď Ž

9. Turn the headlight and ignition switch OFF.

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Charging Circuit Troubleshooting (Without ETCS)

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10. Disconnect the negative cable from the battery.

11. Disconnect ECM/PCM connector B (24P).

12. Check for continuity between ECM/PCM connector terminal B18 and alternator 4P connector terminal No. 2.

ECM/PCM CONNECTOR B (24P)

ACGC (WHT/GRN)

C (WHT/GRN) ALTERNATOR 4P CONNECTOR

Wire side of female terminals

Is there continuity?

YES - Repair the alternator. NO - Repair open in the wire between the alternator and ECM/ PCM.

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Fan Controls Circuit Diagram

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Fan Controls Circuit Diagram

UNDER-HOOD FUSE/RELAY BOX BATTERY

IGNITION SWITCH

No.1 (80A)

No.3 (50A)

BAT WHT

YEL/BLK IG2

No.10 (20A)

No.11 (30A) UNDER-DASH FUSE/RELAY BOX No.22 (7.5A) BLK/YEL

2

5

2

5

RADIATOR FAN RELAY 1

3

CONDENSER FAN RELAY 1

3

GRN

BLU/BLK

GRN

NOISE SUPPRESSOR

GRN

ECM/PCM

BLU/YEL

NOISE SUPPRESSOR

2

2 2 RADIATOR FAN MOTOR 1

RADIATOR FAN SWITCH Closed : Above 93°C (199°F)

CONDENSER FAN MOTOR

1

1

BLK

G301

G101

G301 (With A/C)

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Radiator Fan Circuit Troubleshooting

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Radiator Fan Circuit Troubleshooting 1. Check the No. 10 (20A) fuse in the under-hood fuse/relay box, and the No. 22 (15A) fuse in the under-dash fuse/relay box. Is the fuse (s) OK?

YES - Go to 2.

NO - Replace the fuse (s) and recheck.

2. Remove the radiator fan relay from the under-hood fuse/relay box, and test it. Is the relay OK?

YES - Go to 3.

NO - Replace the radiator fan relay.

3. Measure the voltage between the No. 2 terminal of the radiator fan relay 5P socket and body ground.

RADIATOR FAN RELAY 5P SOCKET

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Radiator Fan Circuit Troubleshooting

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Terminal side of female terminals

Is there battery voltage?

YES - Go to 4.

NO - Replace the under-hood fuse/relay box.ď Ž

4. Connect the No. 1 and No. 2 terminals of the radiator fan relay 5P socket with a jumper wire.

RADIATOR FAN RELAY 5P SOCKET

JUMPER WIRE

Terminal side of female terminals

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Radiator Fan Circuit Troubleshooting

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Does the radiator fan run?

YES - Go to 5.

NO - Go to 6.

5. Disconnect the jumper, and turn the ignition switch ON (II). Check for voltage between the No. 5 terminal of the radiator fan relay 5P socket and body ground.

RADIATOR FAN RELAY 5P SOCKET

Terminal side of female terminals

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Radiator Fan Circuit Troubleshooting

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Is there battery voltage?

YES - Go to 9.

NO - Check for an open in the wire between the under-hood fuse/relay box and under-dash fuse/relay box.ď Ž

6. Disconnect the radiator fan motor 2P connector.

7. Check for continuity between the No. 1 terminal of the radiator fan relay 5P socket and the No. 2 terminal of the radiator fan motor 2P connector.

RADIATOR FAN RELAY 5P SOCKET

Terminal side of female terminals

BLU/BLK Wire side of female terminals

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Radiator Fan Circuit Troubleshooting

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RADIATOR FAN MOTOR 2P CONNECTOR

Is there continuity?

YES - Go to 8.

NO - Repair open in the wire between the under-hood fuse/relay box and the radiator fan motor 2P connector terminal No. 2.ď Ž

8. Check for continuity between the No. 1 terminal of the radiator fan motor 2P connector and body ground.

RADIATOR FAN MOTOR 2P CONNECTOR

BLK

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Radiator Fan Circuit Troubleshooting

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Wire side of female terminals

Is there continuity?

YES - Replace the radiator fan motor.ď Ž

NO - Check for an open in the wire between radiator fan motor 2P connector terminal No. 1 and body ground. If the wire is OK, check for a poor ground at G301.ď Ž

9. Reinstall the radiator fan relay.

10. Disconnect the radiator fan switch 2P connector.

11. Connect the No. 1 and No. 2 terminals, of the radiater fan switch 2P connector with a jumper wire.

RADIATOR FAN SWITCH 2P CONNECTOR

JUMPER WIRE

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Radiator Fan Circuit Troubleshooting

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Wire side of female terminals

Does the radiator fan run?

YES - Replace the radiator fan switch.ď Ž

NO - Go to 12.

12. Remove the jumper wire, and measure the voltage between the No. 2 terminal of the radiator fan switch connector and body ground.

RADIATOR FAN SWITCH 2P CONNECTOR

GRN Wire side of female terminals

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Radiator Fan Circuit Troubleshooting

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Is there battery voltage?

YES - Check for an open in the wire between radiator fan switch 2P connector terminal No. 1 and body ground. If the wire is OK, check for a poor ground at G101.ď Ž

NO - Repair open in the wire between the radiator fan switch terminal No. 2 and the underhood fuse/relay box.ď Ž

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