Withdrawal. 1. Generator connector; 2. Generator mounting bolt; 3. Generator; 4. Terminal wiring «IN»; 5. Terminal nut «IN».
Disassembly. Type: LR1140-802C. 1. Stator assembly; 2. Rotor assembly; 3. Rotor spacer; 4. Clip; 5. Front bearing; 6. Front bracket assembly; 7. Pulley; 8. Pulley cap; 9. Rear bracket assembly; 10. Diode assembly; 11. Double labyrinth seal; 12. Voltage regulator assembly; 13. Back cover; 14. Bushing; 15. Terminal nut «IN».
Removal and installation
Removal
1. Disconnect the cable from the negative terminal of the battery.
2. Remove the engine cover. See chapter «Mechanical part of the engine».
3. Remove the drive belt. See chapter «Mechanical part of the engine».
4. Disconnect the connector (A) from the generator.
5. Unscrew the terminal nut «IN» (A) and disconnect the terminal wiring «IN».
6. Unscrew the top mounting bolt (WITH) generator
7. Loosen the bottom mounting bolt completely (D) generator and remove it until the bolt head touches the side member, then remove the generator from the vehicle towards the front.
Note. The generator can be removed together with the bolts by lifting it forward and using the slot for the bolt of the generator bracket.
8. Remove the generator from the car towards the top.
Installation
Installation is carried out in the reverse order of removal.
Attention:
- Tighten the terminal nut «IN» with caution.
- Hand tighten the alternator bolts in a low to high order, then tighten them in a high to low order.
- Generator surface from the front side (from the pulley side) is a control. Secure the front side to the generator, then tighten the bolts.
- Install the generator and check the belt tension. See chapter «Mechanical part of the engine».
Disassembly and assembly
Disassembly
Rear bracket assembly
1. Remove the back cover.
2. Remove the voltage regulator assembly.
3. Separate the front bracket assembly, stator assembly and rear bracket assembly.
Note. Heat the center of the rear bracket assembly to approximately 30-50°C.
- Insert the tip of a suitable tool into the gap between the front cover and the stator core and separate the front side (front bracket assembly, rotor assembly) and back side (rear bracket assembly, stator assembly, diode assembly).
Attention. Do not damage the stator assembly.
Front cover
1. Secure the rotor in a vice.
Attention:
- Do not damage the rotor.
- When securing the rotor in a vice, lay copper strips or a thick rag.
2. Using a suitable tool, remove the cover from the pulley.
3. Using alternator pulley adapter (special tool) remove the generator pulley.
Assembly
Rear bearing
Attention:
- Once the rear bearing is removed, do not reuse it. Replace with a new one.
- Do not lubricate the rear bearing outer race.
Installing the back cover
1. Install the brush assembly, diode assembly, regulator assembly and stator assembly.
2. Lift the brushes with your fingers and place them on the rotor.
Note. Do not damage the sliding surface of the slip rings.
Examination
Check after disassembly
Rotor check
1. Check resistance.
Resistance: See paragraph below. «Technical data and specifications».
- If the resistance is abnormal, replace the rotor.
2. Insulation check.
- If there is continuity, replace the rotor.
3. Check whether the slip rings are worn.
- Minimum slip ring outer diameter: See paragraph below. «Technical data and specifications».
- If the measured value differs from the norm, replace the rotor.
Checking the brushes
1. Check whether the brushes rotate freely.
- If they rotate with jamming, check the brush holder and clean it.
2. Check whether the brushes are worn out.
- If wear has reached the limit line, replace the brush.
Stator check
1. Conductivity check.
- If there is no continuity, replace the stator
2. Checking conductivity to ground.
- If there is continuity, replace the stator.