Service Procedure
DISASSEMBLING THE ALTERNATOR1. Remove the alternator from the vehicle in accordance with the appropriate Workshop Manual and place the alternator on a work bench.
2. Remove the four M5 through bolts holding the front and rear cover halves together.
3. While holding a heat gun approximately 1/2 inch from the rear cover center, heat up the rear cover for approximately one minute.
NOTE
The heat will cause the rear cover metal to expand slightly, allowing the rear cover to separate more easily from the rotor assembly rear bearing in the front cover half.
CAUTION!
Be careful not to heat the rear cover longer than one minute. Overheating could damage the alternator.
4. Separate the front and rear cover halves by inserting the tips of two screwdrivers into the gap between the front cover and the stator coil and prying the two covers apart at the same time (Figure 2).
CAUTION!
Be careful not to scratch or damage the stator coil with the screwdrivers. To prevent stator coil damage, place some soft material such as a rubber pad, a thick shopcloth, or a piece of cardboard, under the stator coil.
5. Remove the five M5 flange nuts on the back of the rear cover. Remove the M6 battery terminal nut and insulator bushing.
6. Separate the rear cover from the stator by inserting the tips of two screw drivers into the gap and prying the stator and rear cover apart at the same time.
7. Remove the plastic bushing from the battery terminal stud.
8. Remove the three M4 flange bolts holding the diode terminals to the stator terminals, and separate the diode bridge/brush holder assembly from the stator.
REPLACING THE IC REGULATOR
1. Remove the three M4 flange bolts holding the IC regulator and condenser to the diode bridge/brush holder assembly. Separate the IC regulator and condenser from the assembly (Figure 3).
2. Remove the M5 mounting bolt holding the condenser to the IC regulator by lightly tapping on the bolt with a screw driver handle, then separate the condenser from the IC regulator (Figure 4).
3. Attach the condenser to the new IC regulator (Part No. 8-97176-917-0) (Figure 4). Do not install the M5 mounting bolt at this time - this will be done after the rear cover and the diode bridge/brush holder assembly have been reassembled.
CAUTION!
Avoid touching the clear sticky material on the IC regulator opposite the side of the aluminum fins (Figure 5). If this material is touched or disturbed, the IC regulator could be permanently damaged.
4. Install the IC regulator and condenser to the diode bridge/brush holder assembly with the three M4 (8 mm length) flange bolts. Tighten the three M4 flange bolts 14 to 18 lb. in. (1.6 to 2.0 Nm) each (Figure 3).
REASSEMBLING THE ALTERNATOR
1. Install the diode bridge/brush holder assembly to the stator and secure at the diode and stator terminals with the three M4 (4.5 mm length) flange bolts. Tighten the three M4 flange bolts 14 to 18 lb. in. (1.6 to 2.0 Nm) each.
2. Insert the plastic bushing onto the battery terminal stud. Make sure the bushing is inserted with the bevel side down.
3. Press the rear cover onto the stator using both hands. Be sure there are no gaps between the cover and the stator when done.
4. Insert the M5 mounting bolt previously removed from the IC regulator, through the rear cover. Install the insulator bushing onto the battery terminal stud and secure with the M6 battery terminal nut. Install the five M5 flange nuts to the rear cover. Tighten the M6 battery terminal nut 52 to 61 lb. in. (5.9 to 6.9 Nm). Tighten the five M5 flange nuts 27 to 35 lb. in. (3.1 to 3.9 Nm) each.
5. Using your finger, push the two brushes into the brush holder assembly at the same time until the brushes are flush against the assembly opening. While holding the two brushes firmly in place, insert the brush holder pin into the special opening on the rear cover and push down on the pin until the pin engages the holes in the two brushes (Figure 6).
NOTE
When properly engaged, the brush holder pin prevents the brushes from interfering with the rotor assembly slip rings during reassembly of the front and rear cover halves. The brush holder pin can be made from an ordinary 2-inch paper clip that is bent as shown in Figure 7.
If the brushes are worn, you may have difficulty pushing the brushes far enough into the brush holder assembly to allow engagement of the brush holder pin. In this case, use a wooden or plastic stick, (a pencil works well) instead of your finger. Do not use a metal object - this could scratch or damage the brushes.
6. While holding a heat gun approximately 1/2 inch from the rear cover center, heat up the rear cover for approximately one minute.
NOTE
The heat will cause the rear cover metal to expand slightly, allowing the rear cover to fit more easily onto the rotor assembly rear bearing in the front cover half.
CAUTION!
Be careful not to heat the rear cover longer than one minute. Overheating could damage the alternator.
7. Align the front and rear cover halves using the vehicle mounting bolt; then, press the rear cover into the front cover with both hands. Be sure there are no gaps between the cover halves when done.
NOTE
If there is a gap between the cover halves, gently tap the back of the rear cover with a soft hammer until both halves make contact. Be sure not to tap the center portion of the rear cover - this could damage the bearing housing.
8. Insert the four M5 through bolts into the rear cover and remove the vehicle mounting bolt. Remove the brush holder pin from the back of the rear cover. Tighten the four M5 through bolts 27 to 35 lb. in. (3.1 to 3.9 Nm) each.
9. Check the alternator for proper reassembly, by spinning the pulley with your hand and listening for any sounds that could indicate rubbing.
10. Reinstall the alternator into the vehicle using the appropriate Workshop Manual. Be sure that the battery terminal and the harness plug are securely fastened.
CONDUCTING THE PERFORMANCE CHECK
1. Turn the starter switch to the ON position. Check that the charging indicator light comes on.
2. Start the vehicle engine and allow it to idle. Check that the charging indicator light goes out.
3. Rev the engine 2,000 to 3,000 rpm. Using a voltage meter, check the battery voltage output. Voltage should read 12 to 14.5 volts.
IMPORTANT!
If the charging indicator light does not function as described above, or the battery voltage output is not within the specified range, refer to appropriate Workshop Manual for further diagnosis.
APPLYING THE CAMPAIGN LABEL
1. Affix a campaign label (Part No. 2-90028-700-0) adjacent to the manufacturer's identification label located on the driver's side B-pillar.
2. Using a ball-point pen, fill in the label with Campaign Number 97V-034, Isuzu dealer code, and repair date (Figure 8).