Alternator repair (Peugeot 306)

Without the necessary experience, it is prohibited to repair the alternator and the associated voltage regulator. A failed generator can be exchanged at the exchange fund. Minor repairs, such as replacing carbon brushes, can be done in a workshop.

The alternator has lifetime lubricated bearings and requires no regular maintenance. The outside of the generator must be clean and no water or solvents must enter it.

The generator brushes work with a smooth commutator and therefore have a long service life. To check the condition of the brushes, it is necessary to remove the alternator. Below is a description of the disassembly and inspection of the Valeo alternator as installed on most vehicles.

Disassembly

Figure 304 shows the installation drawing of the generator.

• Remove the nut from the rotor shaft and remove the belt pulley, fan and spacer washer from the shaft. When removing the shaft, it is necessary to hold it by placing an old V-belt on the belt pulley and clamping the pulley in a vice, as shown in Figure 305. You can also insert a rod wrench into the hexagon of the shaft when unscrewing the nut. To remove the belt pulley, you will need a puller with two or three jaws.

• Remove the key from the shaft.
• Unscrew and remove the voltage regulator together with the brush holder.
• Mark the drive bearing shield and the generator housing on opposite sides and unscrew both studs from the housing. Separate the rear bearing cover from the front. Lightly tap the front cover with a plastic hammer.
• Place the bearing shield and rotor under a press and remove the rotor using a three-jaw puller, as shown in Figure 306. When pressing out the rotor, the bearing mounting plate screws are stripped. Therefore, it is imperative to ensure that the puller jaws are installed under the bearing mounting plate, and not just under the bearing shield. If you need to remove the bearing from the shield, unscrew the screws from the inside and press out the bearing.

• Press out the bearing from the rotor collector side. If using a puller, position it under the inner bearing race.
• Unsolder the board with diodes from the stator. At the same time, hold the wires at the soldering points with tweezers, which serve as a heat sink. Do not allow the diodes to overheat.
• Rectifier diodes can only be removed if you have the appropriate tools and the necessary knowledge.

Checking the carbon brushes and brush holder

• Check the contact of the brushes with the commutator rings. Check the mobility of the brushes in the guides; if necessary, clean the guides with Tri.
• If the protruding length of the brushes is less than 5.0 mm (Figure 307), new brushes should be soldered in. When the brushes approach this size, they should also be replaced to save on one generator disassembly. Use a ruler for measurements.

Checking the rotor

If the commutator rings are dirty or oily, wipe them with a cloth soaked in "TP" cleaner. Polish any scratches with fine sandpaper. To check the insulation, connect one end of the ohmmeter to the rotor core and the other to the collector rings. If the ohmmeter reading is different from "infinity", the rotor should be replaced. The measurement is carried out as shown in Figure 308.



(Text taken from the website: Peugeotbook.ru)



The rotor winding resistance is checked by connecting both ohmmeter leads to the collector rings (Figure 309). The resistance should be between 3.4 and 3.7 mm. If the resistance is "infinity," there is an open circuit in the winding. If the reading is zero, there is a short circuit in the winding. In both cases, the rotor must be replaced.

Checking the stator

In the case of a short circuit, which is usually the result of severe overheating, the location of the damage is already revealed during an external inspection. Otherwise, connect one ohmmeter lead to the stator lamellar ring and connect the other end in series to each of the three stator winding wires, as shown in Figure 310. The ohmmeter reading should be "infinity" in all measurements. To check the stator winding resistance, connect the ohmmeter leads in series to two of the three winding wires, as shown in Figure 311. If there is no reading, the winding is open. The resistance should be 0.10-0.11 ohms.

Checking diodes

Accurate testing of the electrical characteristics of diodes requires a special test device and should only be performed in a workshop.

Assembly

Figure 304 shows the installation drawing of the Valeo generator; when assembling, please use this drawing.