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HITACHI Alternators: Overhaul: Reassembly

  1. Reinstall diode assembly and stator to rear cover. Solder stator coil lead wires to terminals of diode assembly, taking as little time as possible. Reinstall diode cover.
    NOTE: Soldering must be done quickly to avoid damage to diodes.
  2. Assemble brushes to brush holder, with approximately 0.43" (11 mm) protruding. Insert holder into alternator. Reinstall rotor to front cover.
  3. Place assembly in vise and replace pulley and components. Tighten pulley nut to 29-43 ft. lbs. (39-59 N.m). Insert and tighten housing through bolts to 27-35 INCH lbs. (3-4 N.m).
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