Removing the alternator from the engine
We covered alternator removal and installation in the article – Removing and Installing the Alternator
To repair the alternator, you will need 7mm, 10mm, and 27mm wrenches, a T50 TORX wrench, a tester, a puller, a hammer, and screwdrivers.
Holding the shaft from turning, loosen the pulley mounting nut.
Removing Pulley and spacer ring
Use a marker to mark the relative positions of the stator covers and housing
Pry edge of the casing with a slotted screwdriver.
Remove the casing.
Remove the two mounting bolts. Brush holder
Unscrew the brush holder mounting nut
Remove Brush holder assembly with voltage regulator
Check the brush protrusion.
If dimension "A" is less than 5 mm, replace the brush assembly.
Also check the ease of movement of the brushes.
Check the rotor winding resistance.
The tester readings should show infinity; otherwise, there is an open in the rotor winding and the rotor must be replaced.
Remove the four tie bolts.
Insert a screwdriver between the covers to separate them.
Remove the drive-side cover along with the rotor.
Pressing the rotor out of the front bearing
For Remove the four pressure plate mounting screws from the front rotor bearing.
Removing the plate.
Press the bearing out of the cover.
Press the new bearing into the cover using a suitable-sized mandrel, applying force to the outer ring.
Press the bearing off the rotor shaft using a puller.
Press the new bearing onto the rotor shaft until it stops, applying force to the inner bearing ring.
Check for short circuits between the rotor winding and the housing by connecting it to each slip ring and the housing in turn. Rotor
The tester should read infinity.
Reassemble the generator in reverse order. Orient the covers according to the installed marks.