Reassembly. Volvo Penta D65A MS, D65A MT

Reassembly

Group 23 Fuel System

Reassembly Sequence:

3 9 7 8 6 5 14 12 13 11 10 2 1 4

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173

Group 25 Inlet and Exhaust System

Group 25 Inlet and Exhaust System

Air Cooler

Disassembly

1. Air cooler cover

2. Packing

3. Air cooler element

4. Plate

5. Packing

6. Air cooler case

7. Packing

8. Air cooler element

9. Plate

10. Packing

Look for:

A. Replace packing

174



Inspection

Cleaning air cooler

1.

Remove dirt built up from the air cooler by directing high pressure air of {max press. 0.29 to 0.49

MPa (3 to 5kgf/cm 2 ) [43 to 71 psi]} in the opposite direction of the air flow. Inspect the cooler for corrosion and cracks.

2.

Wash the fresh water or salt water pipes in water and caustic soda lime, then remove scale deposits by inserting a 3 mm [ 1/8 in.] bar into each pipe.

Inspecting air cooler for air tightness

Immerse the air cooler in water, then apply high pressure air {max press. 0.39 MPa (4 kgf/cm 2 ) [57 psi]} to the coolant side to inspect for air leaks.

NOTE! Keep record of the water/air temperatures(using infrared temp. gun) to determine when the cooler needs cleaning.


175


Turbocharger [TD10, TD13]

Disassembly

1. V-clamp

2. Turbine housing

3. Lock plate

4. Compressor cover

5. O-ring

6. Lock nut

7. Compressor wheel

8. Snap ring

9. Insert

10. Piston ring

11. Finger sleeve

12. O-ring

13. Oil deflector

14. Thrust ring (compressor)

15. Thrust bearing

16. Thrust ring (turbo)

17. Shaft and turbine wheel

18. Piston ring

19. Turbine backplate

20. Bearing

21. Snap ring

22. Snap ring

23. Bearing

24. Snap ring

25. Bearing housing

Look for:

A. Wear

B. Thrust face wear

C. Vane distortion, damage, rubbing contact on back face and gas erosion

D. Rubbing contact with compressor wheel

E. Rubbing contact with turbine wheel, cracks and distortion

F. Vane distortion, damage, rubbing contact on back face and gas erosion and damage to ring grooves

G. Rubbing contact with turbine wheel and damage

H. Damage to bearing bore, gas erosion and distortion of turbine side flange

176



Disassembly

Remove the turbine housing

Remove the V-clamp and the turbine housing (in that order) from the turbocharger.

IMPORTANT! The compressor cover, bearing housing and turbine housing must be reassembled in correct orientation. Therefore, put alignment marks with a punch or marker.

Remove the compressor cover

1.

Put the turbocharger on a workbench with the compressor cover down. Unscrew the bolts and remove the lockplates.

2.

Lightly tap around the compressor cover with a soft-faced hammer to remove the cover. Also remove the o-ring from the bearing housing.

Remove the compressor wheel

IMPORTANT! Handle the compressor wheel and turbine wheel with care during disassembly and assembly. Vanes can easily bend when dropped or hit.

1.

Fasten the flange of the turbine housing in a vise and install the bearing housing to the turbine housing with the v-clamp..

2.

Hold the boss of the shaft & turbine wheel and remove the lock nut holding the compressor wheel.

NOTE! The lock nut has left-handed threads.

3.

While holding the turbine wheel with one hand, turn the compressor wheel lightly with the other hand and remove.


177


Removing the snap ring

NOTE! Use only snap ring pliers to remove snap rings.

NOTE! Put your thumb on the snap ring to prevent it from flying out in case the pliers lose grip.

Removing the insert and oil deflector

1.

Using two screwdrivers, gently pry out the insert from the bearing housing.

2.

Separate the finger sleeve together with the piston ring from the insert.

3.

Remove the o-ring, the oil deflector, the compressor thrust ring, the thrust bearing, and the turbo thrust ring from the bearing housing.

Remove the v-clamp

Loosen the v-clamp with a socket wrench and dislodge the clamp from its position

178



Removing the shaft & turbine wheel

1.

Remove the bolts and lock plates.

2.

While gripping the shaft of the shaft & turbine wheel with one hand, hold the bearing housing with the other hand and slowly remove the shaft

& turbine wheel from the turbine housing.

3.

Turn the bearing housing (turbine wheel face up) and place it on the compressor cover. Remove the shaft and turbine wheel, the piston ring, the turbine backplate and the bearing(compressor side).

Removing the snap ring and bearing

IMPORTANT! Remove the snap ring with care and make sure not to damage the inside surface of the bearing house or the seal (turbine side) of the piston ring.

Place the bearing housing on a workbench with the compressor side face up. Then remove the 3 snap rings and the bearing.


179


Inspection

Bearing housing

Measure inside diameter of bearing-fitted section

If the measured diameter exceeds the service limit, replace the bearing housing.

Inside diam. bearing-fitted section, mm [in.]

Service Limit .............

30.006 [1.18134]

Bearing

Measure bearing outside diameter

If the measured diameter is less than the service limit, replace the bearing.

Bearing inside diameter, mm [in.]


29.876 [1.17622]

Measure bearing inside diameter

If the measured diameter exceeds the service limit, replace the bearing.



18.050 [0.71063]

Measuring bearing length

If the measured length is less than the service limit, replace the bearing.

Bearing length, mm [in.]


17.440 [0.68661]

180



Shaft & turbine wheel

Measure journal diam. of shaft & turbine wheel

If the measured diameter is less than the service limit, replace the shaft & turbine wheel.

Shaft journal diameter, mm [in.]


17.996 [0.70850]

Measure shaft deflection

1.

Set a dial gauge at a location next to the threaded section of the shaft, and measure shaft deflection. If the deviation indicated by the dial gauge exceeds the service limit, replace the shaft & turbine w heel.

IMPORTANT! If the shaft is bent, replace.

Do not attempt to correct the bend.

2.

If the surface of the shaft journal is rough, mount the shaft on a lathe, and gently polish the surface using #400 sandpaper and engine oil while rotating at 300-600 min

-1

.

Shaft deflection, mm [in.]


0.015 [0.00059]

Insert

Measure piston ring end gap

Install a new piston ring squarely in the insert then measure the piston ring end gap. If the end gap deviates from the assembly standard, replace the insert.

Ring end gap, mm [in.]

Assembly Standard ...

0.05–0.25 [0.00197–0.00984]


181


Reassembly

Reassembly sequence:

25

24 22

23

21

19

18

17

20 14 13 10 12 11

9

8 7

6

5

4 16

15 3 2

1

NOTE! Always replace the following parts at disassembly:

4. O-ring

9. Piston ring

11. O-ring

19. Piston ring

IMPORTANT! If vanes are damaged or cracked, do not reuse the part.

IMPORTANT! After reinstalling the overhauled turbocharger, crank the engine to lubricate moving parts of the turbo.

182



Install shaft & turbine wheel and bearing

1.

Install the bearing housing, the snap rings and the bearing on the turbine side, and the snap ring on the compressor side.

NOTE! Use only snap ring pliers to install snap rings.

After installing the snap ring, rotate it with a finger to make sure it rotates smoothly.

NOTE! Apply engine oil to the outside and inside surfaces of the bearing before installation.

2.

Place the bearing housing on the compressor cover, and install the turbine backplate.

3.

Insert the piston ring into the groove on the shaft

& turbine wheel

4.

When installing the shaft & turbine wheel mounted with the piston ring in the bearing housing, position the ring on the shaft so that there is a small space (A) at the ring end gap side (B) and a large space (C) on the other side. Then insert the shaft

& turbine wheel while rotating.

IMPORTANT! Do not expand the piston ring excessively or twist the ends when installing on the shaft & turbine wheel.

IMPORTANT! Do not apply excessive forte without tentering the shaft properly during the installation of the shaft & turbine wheel.

NOTE! After installing the piston ring in the ring groove, apply Moly Disulfide to the ring before assembly.

5.

Hold the shaft end and tum the assembly over so the compressor side faces up. Install the bearing on the compressor side and then mount the bearing housing in the turbine housing and fasten the v-clamp temporarily.


183


Install the thrust bearing

Apply engine oil to both sides of the thrust ring and thrust bearing. To install the thrust bearing, align the notch with the groove pin.

Install the O-ring

Apply grease to the O-ring and install.

Install the oil deflector

Apply engine oil to both sides of the thrust ring and install. Then install the oil deflector with the baffle facing down.

184



Assembly of the insert sub-assembly

1.

Install the finger sleeve and the piston ring in the insert.

IMPORTANT! Do not expand the piston ring excessively or twist the ends when installing on the finger sleeve.

IMPORTANT! Apply Moly Disulfide to the piston ring installed on the finger sleeve, then install on the insert carefully so as to avoid piston ring damage.

2.

After installing the above parts, irrstall the sub assembly in the bearing housing.

Install the snap ring

Install the snap ring with the tapered side face up in the bearing housing.

NOTE! Make sure you install the snap ring correctly!

NOTE! Lightly drive both ends of the snap ring using a screwdriver and hammer to securely insert the ring into the groove on the bearing housing. Make sure the screwdriver does not hit the bearing housing.


185


Turbine wheel and housing clearance

Set a dial gauge on the end face of the shaft & turbine wheel. Read the dial gauge indication while moving the shaft & turbine wheel in the axial direction.

If the dial gauge indication deviates from the assembly standard, disassemble and locate the cause of the problem.

Clearance turbine wheel and housing, mm [in.]

Standard Clearance ..

0.29–0.91 [0.01142–0.03583]

Install the compressor wheel

Install the compressor wheel. Apply Moly Disulfide to the threads of the lock nut, then tighten to the specified torque.

Lock nut tightening method

1.

Tighten the lock nut to torque of 49 N

● m (5 kgf

● m)

[36 lbf

● ft], then loosen it completely.

2.

Retighten to a snug torque of 14.7 N

● m (1.5 kgf

● m)

[10.8 lbf

● ft], then turn another 80±3°.

Shaft & turbine wheel axial play

Set a dial gauge on the end face of the shaft & turbine wheel. Measure the amount of play while moving the compressor wheel in the axial direction.

If the measured play deviates from the standard value, disassemble and locate the cause of the problem.

Shaft & turbine wheel axial play, mm [in.]


0.075–0.135 [0.00295–0.00531]

186



Turbine wheel and backplate clearance

Remove the bearing housing from the turbine housing and install it in the compressor cover. Measure the clearance between the turbine backplate and the back side of the turbine wheel using feeler gauges.

NOTE! Use two feeler gauges, and measure at vane tips.

If the clearance deviates from the assembly standard, disassemble and locate the cause of the problem.

Turbine wheel and backplate clearance, mm [in.]

Standard Clearance ..

0.55–1.15 [0.02165–0.04528]

Install the compressor cover

1.

Apply grease to the o-ring and install it.

2.

Mount the compressor cover on the bearing housing and be sure to follow the alignment marks made during disassembly.

Install the lock plates

Install the lock plates to the compressor cover

Install the turbine housing

Mount the turbine housing on the bearing housing and be sure to follow the alignment marks made during disassembly.

Installing the V-clamp

Install the V-clamp to the compressor cover and tap around it with a soft-faced hammer for more than 3 times and tighten to the specified torque.


187

Group 26 Cooling System

Group 26 Cooling System

Fresh Water Pump

Disassembly

1. Snap ring

2. Cover

3. Water pump impeller

4. Ring

5. Unit seal

6. Oil seal sleeve

7. Bearing

8. Water pump gear

9. Bearing

10. Water pump shaft

11. Oil seal

12. Pump case

Look for:

A. Rotation

B. Wear, deterioration of lip

C. Corrosion, chafing

D. Crack, damage

E. Wear, damage

188



Fresh water pump

Touch the drain port located at the bottom of the pump with your finger. If the port is leaking water, check the condition of the unit seal. If it is leaking oil, the oil seal is defective.

Remove the impeller

1.

Remove the snap ring the water pump pliers then remove the cover.

2.

Remove the impeller with the impeller remover.

Remove the water pump shaft

1.

Remove the oil seal sleeve.

2.

Remove the gear and the bearing with the gear puller.

3.

Remove the snap ring of the impeller side ball bearing

4.

Inset the two rings (A) of the ring remover between the unit seal and the pump case.

5.

Fit the outer ring (B) to the outside of the half rings to prevent them from falling down.

6.

Support the pump case and push out the shaft from the impeller side by pushing with a hand press .


189


Inspection

Water pump

Measure the inside diameter of the pump case bore to which the bearing outer race is fitted. Measure the diameter of the pump shaft on which the bearing inner race is fitted. If the bearing, case, or shaft is worn, replace it

Inside diameter of pump case bearing, mm [in.]

Norminal value ..........

Ø120 [4.72]

Assembly standard ...

119.987–120.022 [4.72389–

4.72527]

Pump case bore diameter, mm [in.]


Ø110 [4.33]


110.005–110.040[4.33090–4.33227]

Bearing Diameter, mm [in.]


Ø120 [4.72]


119.985–120.000[4.72381–4.72441]

Bearing Diameter, mm [in.]


Ø110 [4.33]


109.985–110.000

[4.33012–

4.33071]

Bearing Inside diameter, mm [in.]


Ø55 [2.17]


54.985–55.000 [2.16476–2.16535]

Bearing Inside diameter, mm [in.]


Ø50 [1.97]


49.988–50.000 [1.96803–1.96850]

Diameter of pump shaft, mm [in.]


Ø55 [2.17]


55.011–55.024 [2.16578–2.16629]

Diameter of pump shaft, mm [in.]


Ø50 [1.97]


50.011–50.024 [1.96893–1.96944]

190



Reassembly


NOTE! Replace all O-rings, unit seals and oil seals at reassembly.

12 11 5

10 9

8 7 6 4 3 2

1

1.

Use the oil seal installer to drive in the oil seal.

Apply engine oil to seal lip.

2.

Use the unit seal installer to drive in the unit seal.

Replace the unit seal once disturbed.

NOTE! Install the unit seal after coating the outer ring with sealant.

3.

Press the impeller-side of the pump shaft, complete with ball bearings, into the case. Install the snap ring with its gap down.

4.

Press in the unit seal ring with the unit seal floating seat using the ring installer .

NOTE! Before installation coat the floating seat at two locations with LLC solution (anti- freeze).


191


5.

Insert the gear into the shaft by aligning the key.

Press in the ball bearing on the nut side.

6.

Press in the impeller to the depth where impeller’s boss end face is flush with the shaft end.

7.

Mount the cover on the impeller side, and secure it in place with the snap ring.

8.

After installing the water pump assembly, install the alternator pulley and tighten the nut to the specified torque.

192


Thermostats


Disassembly

1.

Thermostat cover

2.

Packing

3.

Snap ring

4.

Thermostat

5.

Thermostat seal

6.

Thermostat case

Look for:

A. Deteriorated, worn, cracked

B. Replace packing

C. Worn, cracked

Inspection

Heat the thermostat in the water. Measure the temperature when the valve opens. Measure it again when the valve lift is 11 mm [0.43 in.]. Replace if not within standard.

Opening temp., °C [°F]


71±2 [159.8±3.6]

Valve lift 11 mm [0.43 in.] temp., °C [°F]


85 [185]

NOTE! Stir the water to maintain even temperatures during the test.

NOTE! Confirm the valve opening temperature

(stamped on its mounting flange).


193


Heat Exchanger

Disassembly

1.

Cover

2.

Packing

3.

Cover

4.

O-ring

5.

Zinc rod

6.

Element

7.

Body

Look for:

A. Pipes clogged, leaks

B. Change if less than 50% remains

Inspection

Cleaning of element

1.

While pouring running water onto the outer surface of the element, clean with a wire brush.

Check the element for corrosion and tears.

2.

Insert a stick into the pipe and remove deposits.

194



Raw Water Pump (standard rubber impeller)

Disassembly

1. Cover, O-ring

2. Impeller

3. Casing, gasket, plate, gasket

4. Bushing, unit seal

5. Slinger

6. Nut, spring washer

7. Pulley

8. Snap ring

9. Shaft, key

10. Bearing

11. Oil seal

12. Holder

13. Cam

IMPORTANT! The rubber impeller is not resistant to anti-freeze or cooling water conditioner.


195


Inspection

Bearing dimensions

Measure the dimensions of the bearing installation sections of the sea water pump holder and shaft. If excessive wear or damage is observed, replace the bearing, holder and shaft.

Inside diameter at bearing position, mm [in.]

Nominal value ...........

Ø110 [4.33]


09.995–110.030 [4.33050–4.33188]

Service limit ..............

110.030 [4.33188]

Bearing outside diameter, mm [in.]


Ø110 [4.33]


109.985–110.000 [4.33011–.3307]



Ø50 [1.97]


49.985–50.000 [1.96791–1.9685]

Shaft diam. at bearing position, mm [in.]


Ø50 [1.97]


50.002–50.013 [1.96858–1.96901]

Service limit ..............

50.000 [1.96858]

196


Reassembly


8 5 12

11

10

9 4

13

3 2 1 7

6



197


1.

Install the cam to the casing, and tighten the screw to the specified torque. The contact surfaces must be coated with ThreeBond 1102.

2.

Install the unit seal to the bushing by striking with a hammer, making sure the unit seal remains square to the bushing during installation. The contact surface must be coated with ThreeBond

1102

NOTE! Be sure to replace the unit seal with a new part

3.

Using a jig and a hammer, install the bearing to the shaft, making sure the bearing remains square to the center line of the shaft.

4.

Install the slinger (A) to the holder. Install the bushing (B) with unit seal to the holder. Clean the sliding surface (C) on the seat side of the unit seal with ethyl alcohol, then coat with turbine oil.

Install the seat side (D) onto the shaft, and fasten with the snap ring (E).

198



5.

Install the casing to the holder via the plate. The contact surface must be coated with ThreeBond

1102. Tighten the bolts to 7.4 to 9.8 N*m (0.75 to

1.0 kgf*m) [5.42 to 7.23 lbf*ft].

6.

Install the impeller to the shaft by striking with a hammer.

NOTE! Make sure the impeller vane tips are pointed in the direction opposite to the rotational direction.

7.

Install the O-ring to the casing, and mount the cover. Tighten the bolts to the specified torque.

8.

Tighten the nut to secure the pulley in place

(tightening torque: 196 N*m (20 kgf*m) [144.7

lbf*ft])


199

Group 30 Electrical System

Group 30 Electrical System

Starter

Disassembly

1.

Safety switch

2.

Magnetic switch assembly

3.

Rear bracket

4.

Brush holder assembly

5.

Yoke assembly

6.

Armature assembly

7.

Center bracket

8.

Shift lever assembly

9.

Front bracket

10. Pinion case

11. Pinion clutch assembly

Look for

A. Wear of gear, damage

B. Play and unsmooth rotation

C. Adhesion of brush particles, irregular wear, brush movement in holder

D. Wear of gear

E. Surface roughness, seizure, wear and damage

200



1.

Remove the safety switch, wires and cables and the magnetic switch assembly.

2.

Unscrew the through bolts and the brush holder mounting screws. Remove the rear bracket.

3.

Remove the brushes from the brush holder assembly and then remove the yoke.

4.

Pull out the armature assembly


201


5.

Remove the center bracket.

6.

Remove the lever pin, inner housing, and shift lever from the pinion case.

7.

Using a jig, remove the pinion stopper, then remove the overrunning clutch from the pinion shaft.

NOTE! To remove the shaft bearing for replacement, use a bearing puller as shown in the drawing.

202



Inspection and Repair

Magnetic Switch

Testing the magnetic switch coil

1.

Test the pressure coil and holding coil for an open ciruit. The coils are open-circuited if there is no continuity between the M terminal of the magnetic switch and the case.

Resistance: 1.4 ohms (approx.)

2.

Apply voltage of 24 volts between the M terminal of the magnetic switch and the case. Now push in the plunger by hand. When you release your hand, the plunger should not be attracted.

Testing magnetic switch contact points

Measure the load current flowing through the starter.

If the voltage drop between terminals B and M exceeds 0.3 volts per 100 amperes, clean or replace the contact points.

If the starter switch is tumed to OFF during voltage measurement, the battery voltage is directly applied to the voltmeter. This can damage the voltmeter. Always turn the starter switch to ON before measuring the voltage, then turn it OFF after measuring the voltage.

IMPORTANT! Do not apply 24 V on terminals to test the magnetic switch movement.


203


Armature

Measuring the armature runout

Measure the runout with a dial gauge. If the deflection exceeds the assembly standard, repair or replace the armature.

Armature deflection, mm [in.]


0.05 [0.00197]

Inspecting the commutator

1.

Check the condition of the commutator surface. If it is rough, polish it with #400 to #600 sandpaper.

Check the commutator for runout with a dial gauge. Replace the commutator if the deflection exceeds the service limit.

Commutator deflection, mm [in.]


0.06 [0.0024] maximum


0.10 [0.0039]

2.

Measure the mica depth. Use a depth gauge to measure the depth of each mica undercut. If the depth exceeds the repair limit, re-condition the mica.

Commutator mica depth, mm [in.]


0.7 to 0.9 [0.028–0.035]

Repair Limit ...............

0.2 [0.0079]

Testing the armature

1.

Use a growler to test the armature for short circuits. If the hacksaw blade vibrates against the core, replace the armature.

2.

If there is continuity between the commutator and shaft, replace the armature.

204



Field coil

Testing for open circuits

1.

If there is no continuity between the M terminal of the field coil and the lead wire on the brush side, replace the field coil.

B

A

Overrunning Clutch

The clutch is in good condition if it rotates freely in one direction when tumed by hand.

Check the pinion teeth for wear or damage. If they are damaged, replace the pinion.

IMPORTANT! Do not immerse the overrunning clutch in cleaning solvent to clean it. Immersion in cleaning solvent Will cause grease inside the clutch to run out, causing clutch parts to seize when operating.

Brushes

Inspecting for wear

Brush height, mm [in.]


21–22 [0.83–0.87](A)


13 [0.51](B)

Testing brush spring tension

Brush spring tension, N (kgf) [lbf]


39.23–49.03 (4.0–5.0 [9–11]


39.23 (4.0 [9] maximum


205


R

Safety Switch

Connect the safety switch as shown, and check the starter and safety switch operations.

1.

Connect the R terminal to the battery minus (-) side.

2.

Turn the switch on, and check that the starter tums.

3.

After step (2) above is completed, if you remove the R terminal from the battery minus (-) side, or if you connect the terminal to the battery plus (+) side after removal, make sure you stop the starter operation.

IMPORTANT! When you are making connections, pay special attention to the battery’s polarity.

206



Reassembly


9 8 10 7 6

5

4 3 2 1

1.

Install the center bracket, overrunning clutch, and pinion stopper to the pinion shaft. Insert the shaft in position by tapping it with a soft-head mallet.

2.

Install the shift lever and pinion shaft to the front bracket by aligning the matching mark on the shifi lever.

3.

Install the armature and yoke to the center bracket, making sure that the dowel pin enters its hole.

4.

Install the brushes and brush holders.


207


NOTE! Install the positive (+) side brush and negative

(-) side brush as shown.

5.

Install the rear bracket to the yoke by aligning the matching marks. Secure the brush holders with bolts, then tighten the through bolts.

6.

Measure the end play of the armature. If the end play exceeds the assembly standard, adjust it on the rear side.

Armature end play, mm [in.]


0.3–0.7 [0.012–0.028]

7.

Liberally coat the internal gear with grease, then install the pinion shaft to the gear.

208



8.

Measure the end play of the pinion shaft. If the end play exceeds the assembly standard, adjust it on the internal gear side.

Pinion shaft end play, mm [in.]


0.2–0.8 [0.008–0.031]

9.

Install the magnetic switch. Apply a voltage of 24 volts between the C and E terminals. Connect the lead wire and energize the circuit between the M and E terminals (within 1 setond). After the pinion has shifted, measure retraction length of the pinion. If the measurement is not within 2.5 to 5.5

mm CO.098 to 0.22 in.], use the magnetic switch adjusting screw to make adjustments.

10. Secure the lead wire.

11. Install the safety switch.


209


Alternator

Disassembly

1.

Nut, washer

2.

Pulley assembly

3.

Set screw

4.

Front bracket assembly

5.

Rotor assembly

6.

Field coil

7.

Stator

8.

Rear bracket

9.

Regulator assembly

10. Rectifier assembly

11. Terminal assembly

210



Inspection and repair

Stator

1.

Testing the stator coil for open circuits

If there is no continuity among the three lead wires, replace the stator.

2.

Testing the stator coil for grounding

If there is continuity between the coil and core, replace the stator.

Field coil

Measure resistance between the terminals of the field coil. If the measured resistance deviates from the standard value, replace the coil.

Field coil resistance,

Ω


7.3–8.6

Inspecting rectifier

To check individual diodes, measure resistance between the diode lead wire and heat sink. Connect the positive (+) test lead wire to the diode and measure resistance. Then, connect the negative (-) test lead wire to the diode and measure resistance again. If both measured values are close to 0 (zero), the circuit is shorted.

NOTE! If the diode has an open circuit or is shorted, it is defective, and the rectifier must be replaced.

Reassembly

Reassembly sequence

8 9 10 11

4 5

7

2

6

1

3

WARNING! The alternator requires no grease.

Keep the bearing box free of oil and grease since oil and grease can cause creeping of the bearing on the rear side.

WARNING! Heat the bearing box of the rear bracket for assembly.


211

Notes

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