This is step-by-step on how to change the Perodua Kancil alternator carbon brush. Alternator plays an important role in the car electrical system, it generate electric to the whole electronic equipment as well as charging the battery. One of the most important part in the alternator in order to generate electric is carbon brush that will be exhausted in 7-8years depend on the usage.
The tools/item needed
1. Spanar/ring no 10,12,and 14. if you wish to clean the interior or the alternator, you will need ring no.8
2. Screw driver. Use high quality one
3. Soldering kit
4. New carbon brush
Before you start, disconnect the positive terminal on the battery to avoid short circut. Then disconnect all the wire connected to the alternator. One socket and another one that is covered by red cap (positive terminal) need to use ring no.10 to remove it.
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1. Alternator bottom bolt
2. Alternator belt
3. Belt tensioner adjuster bolt
4. Positive terminal to battery |
To take out the alternator, there is three bolt need to unscrew. First, the tensioner bolt. After that you can remove the alternator belt. Second the tensioner itself that screwed to the engine block, both use ring/spannar no.12. The third bolt located at the bottom of the alternator, use no.14 ring/spannar. To take out the alternator from the engine bay, you need your personnal skills to do it. As for me, I take it out from below the black aircond hose, loosen any hose/pipe mounting before that to avoid over tension to the hose while the alternator through below it.
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The three zinc cover screw in yellow circle |
Use screw driver to unscrew the three screw behind the alternator to remove the zinc cover. Refer picture above. If you have smaller size of spannar/ring better to use it. I'm not very sure what size it is, but very sure not no.8, maybe no.5/6/7.
After remove the zinc cover, you will find the maroon rubber that cover alternator brush. Unscrew the two screw then you can take out the carbon brush. Refer picture below.
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In the yellow circle is the carbon brush housing, arrow is a rubber carbon brush housing cover |
Remove the exhausted carbon brush solder by using soldering iron and replace it with new one. Make enough hole to insert the carbon brush wire through it. Remember to put the spring first, then the carbon brush. Adjust the carbon brush on same level before you solder it back. If you wish to service or clean the interior, use no.8 spannar to unscrew 4 long screws. I cannot do this because I dont have spannar/ring no.8
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Removing the exhausted carbon brush |
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Carbon housing with new carbon brush. Cut the remaining wire neatly after soldering done. |
Then you can now put all the thing back into its place. When installing back the alternator to its position, screw bolt below the alternator first, second the tensioner mounting and last one the belt tensioner. Use wooden stick or iron rod to push the alternator to tension-up the belt while another hand tighten the tensioner bolt.
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Left: New carbon brush, Right: Exhausted carbon brush. RM3 only. Can buy it from auto sparepart shop. |
Now, you can connect back all the wires and the battery terminal. The radio program preset and digital clock need to set back everytime the the battery terminal disconnected.
Thats all for now.. Just do it and gud luck.