Automotive Technician Training: Practical Worksheets Level 2 by Denton Tom

Author:Denton, Tom
Language: eng
Format: epub
ISBN: 978-1-317-52818-0
Publisher: Taylor & Francis Ltd

Job card

Assessor report

Worksheet 37: Remove and replace alternator strip and replace brushes, regulator and diode pack

Procedure

Disconnect the battery earth or ground lead. Unplug the multi-socket on the rear of the alternator or label and disconnect the cables. Slacken the alternator securing bolts, including the drive belt adjuster strap bolts. Mark the direction of rotation on the belt. Slacken the drive belt tension and remove the belt. Inspect the drive belt and drive pulleys for signs of wear, damage and slipping (glazing on sides).

Hold the alternator secure and remove the securing bolts. Lift out the alternator. Check the spindle bearings by rotating and listening and feeling for uneven and lumpy movement. Check the alternator casing for damage. To remove the pulley, hold the spindle with a key or wrench and a wrench on the pulley securing nut. If the spindle cannot be held, fit an old belt around the pulley and hold the belt in a vice and then turn the pulley securing nut with a wrench. Pull off the pulley. Use a puller if necessary. Lift out the woodruff key if the casing is to be separated. The brushes are usually integral with the regulator on modern alternators. Undo the securing screws on the rear of the alternator and lift out the regulator and brush assembly. Inspect the brushes for length and condition. Inspect the slip rings on the rotor. Remove the rear cover. Undo and remove the through bolts holding the casing halves. Carefully separate the casing making sure that the stator remains in the rear casing and attached to the diode pack. Pull out the rotor from inside the stator.

Remove the circlips retaining the bearings, in each casing half and gently tap out the bearings. Check that the bearings have not been spinning in the casing. Fit new bearings and pack with grease. Fit new circlips and seals. Pre-packed and integral seal bearings are sometimes used. Where a diode pack is available as a replacement, part undo the retaining screws holding the diode pack to the rear casing and unsolder the old diodes where they attach to the stator. Re-solder the new diodes using a heat sink such as a pair of pliers to prevent heat damage to the diodes.

Reassemble the alternator in the reverse order. Spin before refitting to check for abnormal noises. Carry out a bench test if the equipment is available. Refit in the reverse order and adjust the drive belt tension. Run the engine and check that the generator/ignition warning light comes on and then goes out as the engine speed increases. Connect a digital voltmeter and clamp on ammeter and check that the alternator output is correct. Compare with manufacturer’s data.

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