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HITACHI Alternators: Overhaul: Disassembly

NOTE: Alternators for vehicles with diesel engines may vary slightly, due to vacuum pump mounted on alternator.
  1. Remove through bolts. Separate front cover with rotor from rear cover with stator by lightly tapping on front cover with plastic hammer.
  2. Place front cover and rotor assembly in protected vise with pulley nut up. Use aluminum plates if necessary to prevent vise surfaces from damaging rotor.
  3. Remove pulley nut, and take off pulley, fan, and washers. Pull out spacer. Remove rotor. Remove screws from front cover and lift out bearing retainer and bearing.
  4. Remove attaching nuts, and lift stator, diode assembly and brush assembly from rear cover. Using a soldering iron, disconnect diode assembly, brush assembly and IC regulator together from stator leads.
    NOTE: Melting of solder should be done as rapidly as possible to prevent damage to diodes and IC regulator.
  5. To disconnect diode assembly from brush assembly and IC regulator, remove 3 mm rivet and melt solder on terminal "L".
  6. To replace IC regulator, first undsolder regulator terminals, and then remove 2 bolts. Do not remove these bolts unless regulator is to be replaced.
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