GENERATOR
Starting/Charging Systems
- Non-Turbo Model
3. Generator
S179008
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A: REMOVAL
S179008A18
1) Disconnect battery ground cable.
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- Turbo Model
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2) Disconnect connector and terminal from gen­erator. - Non-Turbo Model
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4)   Remove front side V-belt.
<Ref. to ME(SOHC) -42, FRONT SIDE, REMOVAL, V-belt.> or <Ref. to ME(DOHC TURBO) -44, FRONT SIDE, REMOVAL, V-belt.>
5)   Remove bolts which install generator onto bracket.
- Turbo Model
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3) Remove V-belt cover.
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GENERATOR
Starting/Charging Systems
3) Hold rotor with a vise and remove pulley nut.
B: INSTALLATION
S179008A11
Install in the reverse order of removal.
CAUTION:
Check and adjust V-belt tension. <Ref. to
ME(SOHC) -43, INSPECTION, V-belt.> and <Ref.
to ME(DOHC TURBO) -45, INSPECTION,
V-belt.>
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CAUTION:
When holding rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of the vise to prevent rotor from damage.
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C: DISASSEMBLY
S179008A06
50C
1) Heat the portion (A) of rear cover to (122F) with heater drier.
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(A)     Front bracket
(B)     Pulley
(C)    Nut
(D)    Rotor
4) Unsolder connection between rectifier and sta­tor coil to remove stator coil.
CAUTION:
Finish the work rapidly (less than three sec­onds) because the rectifier cannot withstand heat very well.
2) Remove the four through bolts. Then insert the tip of a flat-head screwdriver into the gap between the stator core and front bracket. Pry then apart to disassemble.
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GENERATOR
Starting/Charging Systems
5) Remove screws which secure IC regulator to rear cover, and unsolder connection between IC regulator and rectifier to remove IC regulator.
CAUTION:
Be sure to remove the wire after reassembly.
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2)   Heat the bearing box in the rear bracket [50 to 60C (122 to 140F)] and press the rear bearing into the rear bracket.
CAUTION:
Grease should not be applied for the rear bear­ing. Remove oil completely if it is found on the bearing box.
3)  After reassembly, turn the pulley by hand to check that the rotor turns smoothly.
6) Remove the brushes by unsoldering at the pig­tails.
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E: INSPECTION
S179008A10
1. DIODE
S179008A1001
CAUTION:
Never use a megger tester (measuring use for high voltage) or any other similar measure for this test; otherwise, the diodes may be dam­aged.
1) Checking positive diode Check for continuity between the diode lead and the positive side heat sink. The positive diode is in good condition if continuity (1 D. or less) exists only in the direction from the diode lead to the heat sink.
7) Remove the nut and insulating bushing at ter­minal B, and remove rectifier.
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(A)     Ractifier
(B)     Rear cover
(C)    Nut
D: ASSEMBLY
S179008A02
To assemble, reverse order of disassembly. 1) Pulling up brush
Before assembling, press the brush down into the brush holder with your finger and secure in that position by passing a [2 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the hole shown in the figure.
(A)     Diode lead
(B)     Heat sink (Positive side)
2) Checking negative diode Check for continuity between the negative side heat sink and diode lead. The negative diode is in good condition if continuity (1 D. or less) exists only in the direction from the heat sink to the diode lead.
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GENERATOR
Starting/Charging Systems
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4) Insulation test
Check continuity between slip ring and rotor core or shaft. If continuity (1 D. or less) exists, the rotor coil is grounded, and so replace rotor assembly.
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(A)     Diode lead
(B)     Heat sink (Negative side)
2. ROTOR
S179008A1002
1)  Slip ring surface
Inspect slip rings for contamination or any rough­ness of the sliding surface. Repair slip ring surface using a lathe or sand paper.
2)  Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn replace rotor assembly.
Slip ring outer diameter: Standard
22.7 mm (0.894 in) Limit
22.1 mm (0.870 in)
3)  Continuity test
Check resistance between slip rings using circuit
tester.
If the resistance is not within specification, replace
rotor assembly.
Specified resistance: Approx. 2.7-3.2 D.
5) Ball bearing (rear side)
(1)  Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly.
(2)  The rear bearing can be removed by using common bearing puller.
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3. STATOR
S179008A1003
1) Continuity test
Inspect stator coil for continuity between each end of the lead wires. If there is no continuity (1 D. or more) between individual lead wires, the lead wire is broken, and so replace stator assembly.
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GENERATOR
Starting/Charging Systems
2) Insulation test
Inspect stator coil for continuity (1 D. or less) between stator core and each end of the lead wire. If there is continuity, the stator coil is grounded, and so replace stator assembly.
2) Checking brush spring for proper pressure Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of the brush spring. If the pressure is less than 2.648 N (270 g, 9.52 oz), replace the brush spring with a new one. The new spring must have a pressure of 4.609 to 5.786 N (470 to 590 g, 16.58 to 20.81 oz).
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4. BRUSH
S179008A1004
1) Measure the length of each brush. If wear exceeds the service limit, replace the brush. Each brush has the service limit mark (A) on it.
Brush length: Standard
18.5 mm (0.728 in) Service limit
5.0 mm (0.197 in)
5. BEARING (FRONT SIDE)
S179008A1005
1)  Check front ball bearing. If resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing.
2)   Replacing front bearing
(1)   Remove front bearing retainer.
(2)  Closely install a fit tool on the bearing inner race. Press the bearing down out of front bracket with a hand press or vise. A socket wrench can serve as the tool.
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(A)     Front bracket
(B)    Socket wrench
(3)  Set a new bearing and closely install a fit tool on the bearing outer race. Press the bear­ing down into place with a hand press or vise. A socket wrench can serve as the tool.
(4)   Install front bearing retainer.
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GENERATOR
Starting/Charging Systems
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(A)     Bearing
(B)    Socket wrench
(C)    Front bracket
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