Part 1. Preparation and safety
Objective
- Safely remove and replace a vehicle’s alternator.
Personal safety
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection – such as rubber gloves and barrier cream
- Respiratory equipment – such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
Safety check
- When disconnecting a battery always disconnect the negative terminal first.
- When reattaching a battery always attach the negative terminal last.
- Do not wear jewelry that may cause a short circuit with an electrical connection.
- Alternators produce heat when operating. Make sure you test the temperature of the alternator before you handle it.
- Always wear protective clothing and the appropriate safety equipment.
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Vehicle alternators are designed for use only on a negative earth system.
- The alternator must not be operated with the battery disconnected or the terminals at the back of the alternator disconnected.
- Do not short circuit the alternator by connecting the battery connection directly to the engine or vehicle body.
- Even though most vehicle electrical systems are described as being 12 volt, they operate at between 13.8 to 14.2 volts. If the system is not operating at this value the alternator or the voltage regulator are faulty
- When removing electrical wires and connections make sure you refit the securing fastener to its thread so it doesn't get lost.
Part 2: Step-by-step instruction
- Disconnect the battery terminal
Locate the battery and its negative terminal. Loosen the terminal clamp and remove the terminal from the battery post. Store the terminal so it cannot come in contact with the battery post while you are working on the vehicle.
- Loosen the drive belt
Fit fender covers to the vehicle. Loosen the drive belt and remove it from the alternator pulley. Check the condition of the belt to see if it is still serviceable.
- Remove electrical connections
Locate the electrical connections at the rear of the alternator and note their positions. Loosen any securing fasteners or covers and remove terminals one at a time. In some cases the electrical terminals are encased in a plug.
- Remove the alternator
Loosen the securing fasteners that hold the alternator to its mounting bracket making sure that the alternator is supported. Next remove the fasteners completely and then remove the alternator from the engine bay.
- Refit the alternator
Locate the alternator in the mounting bracket and, while still supporting the alternator, loosely fit the securing fasteners that hold the alternator to its mounting bracket.
- Attach electrical connections
Refit the electrical wires to their correct terminals referring to the manufacturers manual to check the connections are correct. Once all the wires are fitted check the security of any fastening device.
- Refit drive belt
Fit the drive belt over the alternator drive pulley and using the correct tools, adjust the belt to the correct tension. The belt should not be over tightened to prevent damage in service.
- Refit the battery terminal
Locate the battery terminal connection and reattach it to the negative post of the battery. Make sure that the fastener is tight. Replace any battery post covers.
- Test alternator output
Turn the ignition switch to the ON position and make sure the charge light on the vehicle dash panel is illuminated. Start the engine and with a DVOM set to read DC voltage, place the positive probe onto the battery positive and the negative probe to the battery negative. Raise the engine speed to 2000 rpm and check that the DVOM is reading 13.8 to 14.2 volts.
- Clean up
Remove the fender covers and return any tools used to their correct place.
Source: CDX Global
