REMOVAL & INSTALLATION
All models are equipped with internal voltage regulator. Since the regulator is part of the alternator, no adjustments are possible or necessary.
- Disconnect the negative battery cable.
- Remove the alternator from the vehicle.
- Carefully remove the 3 or 4 long through bolts. Be careful not to damage the bolt head. Place a matchmark on the 2 case halves before disassembly.
- Lightly tap on the rear housing and separate the 2 housings. If the halves will not come apart. Heat the rear housing bearing boss with a 200 watt soldering iron. Do not use heat gun, internal components may be damaged.
- Remove the diode and brush holder assembly nuts from the rear case. Label all nuts and insulators before removal.
- Remove the IC regulator from the housing.
- Remove the brushes from the brush holder. Some units have soldered brush wires. Using a 200 watt soldering iron, remove the brush wire from the brush holder.
- Install the brush into the holder so the wire is through the hole.
- Solder the wire and make sure the brush moves freely inside the brush holder.
- Install the brush holder, IC regulator and diode assembly into the rear case. Install the retaining nuts and insulators. Torque the nuts to 36 inch lbs. (4 Nm).
- Push the brushes into the holder and insert a wire through the rear housing into the brush holder to retain the brushes during installation.
- Carefully install the 2 case halves together, making sure the brushes are held in place.
- After the halves are together, install the through bolts and torque to 48 inch lbs. (5.5 Nm).
- Remove the brush retaining wire and install the alternator to the vehicle.
- Adjust belt tension and reconnect all wiring.
- Start the engine and check operation.