Turn ignition switch OFF and disconnect the negative (-) battery terminal.
Remove the diesel fuse & relay box (A) after loosening the mounting bolts and nut.
Lift the vehicle.
Remove the engine room under cover (A).
Remove the front driveshift RH.
(Refer to Driveshaft and axle - "Front Driveshaft")
Using the hexagon wrench, turn the tensioner (A) counterclockwise and loosen. Then remove the drive belt (B).
Disconnect the alternator connector (A), and remove the cable (B) from alternator "B" terminal.
Remove the alternator under mounting bolt (A).
Lift the RH side of the engine with a jack (A).
Remove the alternator upper mounting bolt (A).
Remove the alternator.
Remove the alternator cover after loosening the B terminal mounting nut(A) and rear cover nut(B).
Loosen the mounting bolts(A) and disconnect the brush holder assembly(B).
Remove the pulley(A) using the special tool.
Unsolder the 3 stator leads(A).
Loosen the 4 through bolts(A).
Disconnect the rotor(A) and bracket(B).
Reassembly is the reverse order of disassembly.
Check that there is continuity between the slip rings (C).
Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).
If the rotor fails either continuity check, replace the alternator.
Check that there is continuity between each pair of leads (A).
Check that there is no continuity between each lead and the coil core.
If the coil fails either continuity check, replace the alternator.
Install in the reverse order of removal.
Adjust the alternator belt tension after installation.
(Refer to Engine Mechanical System - "Drive Belt")
Alternator installation bolt:
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
Alternator B-terminal cable installation nut:
9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 Ib-ft)