Download INSTALLATION INSTRUCTIONS WARNING!!

INSTALLATION INSTRUCTIONS WARNING!!
The following instructions must be followed or damage will occur to the alternator.
*** YOU MUST DO STEPS 1, 2, AND 6 ***
INSTALLATION INSTRUCTIONS
1
2
!! WARNING!!
With engine stopped,
disconnect battery. Negative cables must be
disconnected or regulator damage will occur.
5
Adjust belt tension.
1/4" DEFLECTION
!! WARNING!!
Install charger and charge battery. Battery
must be recharged or alternator
will be damaged.
6
!! WARNING!!
Perform VOLTAGE DROP TEST, AND
GROUND CIRCUIT TEST.
as illustrated.
3
Note connections
and remove alternator.
VOLTAGE DROP TEST: Perform this test under full load (all lights, fan,
A/C, etc. on) with engine running at 2000rpm.
Reading on voltmeter should be less than .2 volts.
4
Install new alternator
and NEW belt.
7
GROUND CIRCUIT TEST: Perform this test under full load (all lights,
fan, A/C, etc. on) with engine running at 2000rpm.
Reading on voltmeter should be less than .2 volts.
PI0054/1 of 2/v1.0
PRODUCT ADVISORY
This advisory is to inform you and your customers of vehicle problems that are common with the vehicle on
which this unit is being installed.
APPLICATION:
1993- 1995 Geo Prizm 1600, 1800 cc
1993- 1995 Toyota Corolla (AE101,102)
PROBLEM: Premature alternator failure due to excessive loads placed on the alternator. The most common
cause of failure is using the alternator to charge a low or dead battery. You must check battery specific
gravity and test for system voltage drops.
CAUSE: Low battery voltage resulting in high output demands on the alternator. Low battery voltage can be
due to a marginal battery or voltage drops in the B+ circuits.
You MUST do the following step before removal.
1. Disconnect negative battery cable before removing alternator. You may damage your vehicle or the
alternator if you fail to remove negative cable.
You MUST do the following step before installation of alternator.
2. Charge your battery. Battery must be fully charged before alternator installation. Specific gravity
must be 1.28 g/cm3 , Open Circuit Voltage (across battery) must be 12.6 volts after charging battery.
You MUST do the following step after alternator installation.
3. Perform voltage drop steps as shown in step #6 on other side of page.
Warranty will be void if theses steps are not followed.
Failure to perform the above steps may result in damage to your vehicle or alternator.
PROBLEM: Alternator will not charge when installed.
Cause: No voltage to alternator plug.
With ignition switch in the on position check for voltage (with test light) on vehicle
harness that plugs into alternator. Flex harness when checking and inspect each terminal in harness.
Check each terminal
Light must come on.
Light must be
bright
Vehicle Plug-->
Test light
Ground
PI0054/2 of 2/v1.0