AURETR029 - Assessment 1 - Written Knowledge - Questions - V2

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AURETR029 Diagnose and repair charging systems

Assessment 1 – Questioning – Written Assessment

Student Name Amarpreet Singh Student ID Number 20210167

Unit Start Date Unit End Date

Assessment Due Date Date Submitted 29/11/2021

This cover sheet is to be completed by the student and assessor and used as a record to determine student
competency in this assessment task

The assessment process and tasks were fully explained. Yes / No

I am aware of which evidence will be collected and how. Yes / No

I am aware of my right to appeal an assessment decision. Yes / No

I am aware that I can locate The RTO Complaints and Appeals Policy and Procedure on their Yes / No
website at (Insert Website Link)

I have discussed any additional educational support or reasonable adjustments I require in order to
undertake this assessment with the Student Support Services Officer and Trainer / Assessor, (if Yes / No
applicable). e.g. Student Handbook and Access and Equity Policy (Insert Website Link)

I have access to all required resources? Yes / No

Cheating & Plagiarism Declaration

Student Declaration: In accordance with The RTO Plagiarism Policy, I hereby acknowledge by signing this
declaration that I have not cheated or plagiarised any work regarding the assessment tasks undertaken in this unit
of competency except where the work has been correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor

Signature Amarpreet Singh Date: 29 / 11/ 2021

Satisfactory or Not Yet Satisfactory


Assessment Results
(Please circle the assessment result for this task)

Feedback to Student - Please provide general feedback on the Student’s performance

Student Declaration: - I verify that the work completed Assessor Declaration: - I verify that I have adequately
is my own and that I was adequately informed of the explained and negotiated the assessment tasks with the
assessment process prior to commencing this student prior to commencing assessment.
assessment task.

Student Name: Amarpreet Singh Assessor’s Name:


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AURETR029 Diagnose and repair charging systems

Student Signature Date Assessor Signature Date


Amarpreet Singh
29/11/2021

Student Guide for Written Knowledge Assessment


Overview of This is a written assessment task you will be assess on your knowledge of diagnosing and
Assessment repairing charging systems.
The topics that will be covered in the assessment are:
1. Prepare to diagnose and repair charging systems
2. Diagnose charging system
3. Repair charging system
4. Complete work processes
This assessment will ensure that the elements, performance criteria, performance evidence
and knowledge evidence required, and conditions are adhered to demonstrate competency
in this unit assessment task.
 Read the assessment carefully before commencing.
 Your Assessor will use the assessment criteria in this document and will provide
feedback / comment.
 You MUST answer all the questions in the assessment tasks in your own words and
own handwriting.
 This is an “Open Book” assessment, and students can use the resources listed in
the “Resources Required” section below.

Task/s to be To complete this written assessment, you will need to answer the 61 questions comprising
assessed of Multiple Choice, True and False, Fill-in the Gap and Short Answer questions.

Time allowed On average, the Assessment should take 4 – 6 hours to complete.

Location This theory assessment will be completed in a classroom under the supervision of a
trainer/assessor.

Decision making To receive a ‘satisfactory’ outcome for this assessment students MUST successfully answer
rules all questions. If a student achieves less than 100%, they can reattempt the assessment
after further study has taken place. Students who cannot achieve a minimum of 100% you
will not have satisfactorily completed this assessment
Your assessor will be looking for the following in this assessment task: -
 Work health and safety (WHS) and occupational health and safety (OHS)
requirements relating to diagnosing and repairing charging systems, including
procedures for: 
o Using specialised tools and equipment 
o Using appropriate personal protective equipment (PPE) 
o Identifying hazards and controlling risks associated with: 
 Working on high voltage ignition systems 
 Wearing jewellery while working around high current wiring
systems 
 Operating principles of charging systems and associated components, including: 
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AURETR029 Diagnose and repair charging systems

o Charging batteries with direct current 


o Vehicle system power and electrical current requirements 
o Generating principles, including Faraday’s law and inducing an
electromotive force (EMF) 
o Producing direct current (DC) EMF 
o Producing alternating current (AC) EMF 
o Changing AC to DC, including half-wave and full-wave rectification 
 Application, purpose and operation of charging systems and components,
including: 
o Generators, including: 
 Internal component function and operation 
 Regulation of output voltage and current 
o Alternators, including: 
 Internal component function and operation 
 Star-connected and delta-connected stator windings 
 Regulation of output voltage, including zener diodes and exciter
diodes 
o Battery management systems 
 Diagnostic testing procedures for charging systems, including: 
o Accessing and interpreting scan tool system data, including: 
 Diagnostic trouble codes (DTCs) 
 Live data 
 Freeze frame data 
 Waveforms 
o Using diagnostic flow charts 
o Testing electrical systems, including procedures for: 
o Accessing electrical terminals and using test probes without damaging
connectors, fuse holders or wiring 
o Load testing charging systems 
o Resistance, current flow and voltage drop checks of charging system
circuits 
 Repair procedures for charging systems, including: 
o Tightening connections 
o Replacing faulty or damaged cable connections 
o Removing and replacing faulty or damaged components 
 Post-repair testing procedures for charging systems, including: 
o DTC clearing procedures 
o Checking for electrical connector mating 
o Static and dynamic performance tests of charging systems.

Assessment Assessors MUST satisfy NVR/AQTF assessor requirements. 


conditions
Competency is to be assessed in the workplace or a simulated environment that accurately
reflects performance in a real workplace setting. 
Assessment MUST include direct observation of tasks. 
Where assessment of competency includes third-party evidence, individuals MUST provide
evidence that links them to the charging systems that they have worked on, e.g. repair
orders. 
Assessors MUST verify performance evidence through questioning on skills and knowledge
to ensure correct interpretation and application. 

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AURETR029 Diagnose and repair charging systems

The following resources MUST be made available: 


 Automotive repair workplace or simulated workplace 
 Workplace instructions 
 Manufacturer specifications for vehicle, vessel or machinery charging systems 
 Two different vehicles, vessels or machinery with charging system faults 
 Diagnostic equipment for vehicle, vessel or machinery charging systems, including: 
o Multimeter 
o Scan tool 
 Tools, equipment and materials appropriate for repairing vehicle, vessel or
machinery charging systems. 

Resources required Learning Resources available to students include:


 Automotive Technology (A System Approach) 6th Edition – Chapters 6, & 19
 Websites –
 https://www.autocodes.com/p0562.html
 https://www.autocodes.com/p0563.html
 https://www.autocodes.com/p2503.html
 https://www.autocodes.com/p0622.html
 http://www.autoshop101.com/trainmodules/alternator/alt101.html
 http://cartech.about.com/od/Power/fl/Understanding-Alternator-Output-Ratings.htm
 http://www.bcae1.com/charging.htm
 https://en.wikipedia.org/wiki/Rectifier
 http://www.waybuilder.net/sweethaven/MechTech/Automotive/
Automotive02/default.asp?iNum=1&uNum=030101
 http://www.autocodes.com
 http://www.trouble-codes.com
 Trainer Handouts

Results/Re-  The Assessor will grade the assessment and record the result on the front page of
assessment this document (S) – Satisfactory if all observable behaviours are correct and (NS)
not satisfactory if any areas are left incorrect
 Feedback will be provided on either result
 Where a student receives a ‘NS – Not Satisfactory’ result, the assessor will discuss
the area of the non-compliant observable behaviour and an opportunity given for re-
assessment. This may be through direct observation or a different method of
assessment e.g. verbal/oral questioning, problem solving exercise.
 If the outcome is again not satisfactory the student result will be deemed (NYC) not
yet competent. Additional feedback will be given, and a time agreed upon for further
assessment after additional training and skills practice has taken place, this
information will be recorded, dated and signed in the re-assessment area on the
last page of this document
 Where all the assessment tasks have been graded (S) Satisfactory, the student will
be deemed C – Competent for the practical component and the result recorded and
signed in the area indicated on the last page of this document

Reasonable If the participant is unable to undertake the written assessment as designed, an interview
Adjustment (verbal questioning) may be used as an alternate approach.

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AURETR029 Diagnose and repair charging systems

Assessment 1 – Questioning

Written Assessment

1. Why should you NEVER use a test-light to diagnose components and wires in computer systems?
Because the current draw of these test lights may damage the computer system components.

High-impedance test lights are available for diagnosing computer systems.

2. NEVER use a test light to probe for power in an electronic circuit.


Never use a test light to probe for voltage because they have electricity running through them

and can give a dangerous shock

3. You should NEVER connect a ‘self-powered’ test-light to a circuit that is powered. Why?
A powered test light should only be used if the power for the circuit or component has been

disconnected because a self-powered test light is used to check for continuity. The light turns on if the circuit is
completed

4. Analogue meter cannot be used on a computer-controller circuit unless expressly directed to do so in the
workshop manual. Why?
Because they have low internal resistance(input impedance). The low input impedance allows

too much current to flow through circuits and can damage delicate electronic devices

5. Explain why the leads of an ammeter should NEVER be place the across the battery or a load.
Never place the leads of an ammeter across the battery or a load. This puts the meter in parallel

with the circuit and will blow the fuse in the ammeter or possibly destroy the meter

6. Identify five (5) important items of personal safety when diagnosing and repairing charging systems.

1 Safety Glasses

2 Proper Clothing

3 Safety Gloves

4 Safety Boots

5 Hearing Protection
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7. State the precautions that should be observed when working around high voltage ignition systems.

1 Disable or disconnect the high voltage system before performing services to those systems.

2 Make sure the power to the electric motor is disconnected.

3 Always use insulated tools.

4 Wear insulating gloves also called “line-man’s gloves”.

5 Always install the correct type of circuit protection device into a high voltage system.

6 All high voltage wires and harnesses are wrapped in orange coloured insulation stay away from it
unless

8. Rings, necklaces, bracelets and watches should not be worn while working around charging systems. Why?
Because jewelry conduct electricity very well and can easily cause a short, through you, if it touches a bare

wire.

9. Explain the purpose of the “Charging System”?


The primary purpose of a charging system is to recharge the battery. The charging system recharges the

battery by supplying a constant and relatively low charge to the battery.

10. What are DC generator and what do they do?


The DC generator provides direct current (DC) and is similar to an electric motor in construction. In a DC

generator, the placement of the brushes on the commutator changes the induced AC voltage to a DC voltage
Output

11. Explain how a DC generator works?


The armature in a DC generator is driven by the engine. It is not magnetized and the windings simply rotate

through the stationary magnetic field of the field windings, inducing a voltage in the conductors inside the

armature. In a DC generator, the placement of the brushes on the commutator changes the induced AC

voltage to a DC voltage output.

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12. Why don’t modern vehicles use DC generators?


DC generators had a very limited current output, especially at low speeds. They could not keep up with

demands of the modern automobile and were replaced by AC generators.

13. The output of an alternator is usually expressed in.


Ampere (amp).

14. If an alternator rotor has a resistance of 6 ohms. What will the average rotor current be when the output is 25
amps, the reference voltage 14.25 volts and the average voltage switched by the regulator 12 volts? Use
Ohms Law

= = =

15. As the battery voltage increases what happens to the alternator current? Why?
Higher sensing voltage will result in a decrease in field current and voltage output. The regulator will reduce

the charging voltage until it is at a level to run the ignition system while putting a low charge on the battery.

This is done to ensure that the battery stays fully charged

16. All charging systems use what principle to generate the electrical power?
Charging systems work on the principles of magnetism to change mechanical energy into electrical

17. Describe the principle of “Faraday’s Law”?


law stating that when the magnetic flux linking a circuit changes, an electromotive force is induced in the

circuit proportional to the rate of change of the flux linkage

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18. Describe the difference between alternating and direct current?


In direct current, the electrons flow in one direction only whereas in alternating current the electrons change

direction at a fixed rate.

19. How is AC changed to DC in an alternator?


In an AC generator, current is rectified (changed from AC to DC) through the use of diodes. The diodes are

arranged so that current can leave the generator in one direction only (as DC).

20. In an AC alternator, how is half wave and full wave rectification produced?

Half wave:
When AC passes through a diode If the diode is reversed, it blocks off current during the

positive pulse and allows the negative pulse to flow. Because only half of the AC current
pulses

is called half wave rectification.

Full wave: By adding more diodes to the circuit, more of the AC is rectified. When all of the AC is
rectified,

full wave rectification occurs.

21. How does a DC generator operate?


The DC generator provided direct current (DC) and was similar to an electric motor in construction.

The armature in a DC generator is driven by the engine. It is not magnetized and the windings simply rotate

through the stationary magnetic field of the field windings, inducing a voltage in the conductor inside the

armature. In a DC generator the placement of the brushes on the commutator changes the induced AC

voltage to a DC voltage output.

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22. Name the nine [9] components of a DC generator.

1 Pole

2 Commutator

3 Top Brush

4 Commutator segments

5 Pole shoe

6 Field windings

7 Bottom brush

8 Armature

9 Yoke

23. How is voltage controlled in a DC generator and how does it operate?


In a DC generator, the placement of the brushes on the commutator changes the induced AC voltage to a DC

voltage output. The armature in a DC generator is driven by the engine It is not magnetized and the windings

simply rotate through the stationary magnetic field of the field windings, inducing a voltage in the conductors

inside the armature.

24. How is current controlled in a DC generator and how does it operate?


DC generators had a very limited current output, especially at low speeds The armature in a DC. generator is

driven by the engine It is not magnetized and the windings simply rotate through the stationary magnetic field

of the field windings, inducing a voltage in the conductors inside the armature.

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25. Name the ten [10] components of an alternator?

1 Pulley 6 Protective Cap

2 Roller Bearing 7 Regulator

3 Roller bearing 8 Stator

4 Collector – ring end shield 9 Rotator

5 Rectifier 10 Drive end Shielf

26. Explain the purpose of the rotor?

rotates as a result of the repulsion and attraction of the magnetic poles.

27. How does the rotor become magnetic?


The rotor is a rotating magnetic field inside the alternator. A magnetic field is formed by a small amount (4.0 to

6.5 amperes) of current passing through the coil winding

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Multiple Choice question. Selected the correct answer.


28. Which part of the AC alternator produces the moving magnetic field?

A. Stator.
B. Rotor.
C. Brushes.
D. Poles.

29. What do slip rings and brushes do?


Slip rings and brushes conduct current to the spinning rotor.

Multiple Choice question. Selected the correct answer.


30. Slip rings and brushes?

A. Mount on the rotor shaft.


B. Conduct current to the rotor field coils.
C. Are insulated from each other and the rotor shaft.
D. All of the above.

31. Explain the purpose of the stator?


The stator is the stationary member of the generator. It is made up of a number of conductorsor wires, into

which the voltage is induced.

32. What does the ‘End Frame’ assembly house?


The end frame assembly, or housing, contains the bearings for the rotor shaft. Each end frame also has builtin

ducts so the air from the rotor shaft fan can pass through the AC generator.

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33. Why does the alternator require a cooling fan?


Cooling fan rotates with the rotor. This cooling fan draws air into the housing through the openings

at the rear of the housing. The air leaves through openings behind the cooling fan. The moving

air pulls heat from the diodes and their heat decreases.

34. Most alternators use three (3) windings to generate the required amperage output. Draw and name them
below.

35. Alternating current produces positive and negative pulses. The resultant waveform is a sine wave, which can
be observed on a scope. Draw the 3-phase sine wave below.

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36. What do “Diodes” do?


A diode allows current to flow in one direction but not in the opposite direction. Therefore it can function a

switch, acting as either conductor or insulator, depending on the direction of current flow

37. What is the purpose of the exciter diodes?


The main purpose of exciter in a alternator is to provide stationary rotating magnetic field. Which is used to

induce the electromotive force in the armature coil.

38. What is an electronic voltage regulator?


Electronic voltage regulator can be mounted outside the generator or be an integral part of the generator

39. Explain how a simple electronic-voltage regulator works?


An electronic voltage regulator have a zener diode that blocks current flow until a specific voltage is obtained,

at which point it allows the current to flow

40. What is the purpose of a Zener diode in an electronic voltage regulator?


A zener diode in an electronic voltage regulator blocks current flow until a specific voltage is obtained, at

which point it allows the current to flow.

41. In regards to the charging systems, what does the PCM control?
PCM controls the generator by controlling the duty cycle of the field current. The PCM can also increase the

idle speed of the engine to raise charging rates in order to meet the current needs. The PCM will also change

42. How does voltage regulation circuitry located within a PCM control the alternator output?

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It adjusts the duty cycle of the field current to control the alternator output.

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43. How can an oscilloscope be used to check alternator output?


An oscilloscope checks alternator output by showing voltage patterns.

44. Identify the following charging system DTC’s, their meaning, the symptoms and common problems.

Fault code: P0562


Fault Code Definition:

P0562 Description:
When the code p0562 is set in the powertrain computer,it means that the PCM is seeing a lower than

requested vehicle voltage.The code will set when the voltage level goes below 10.0 volts for more than

60 seconds while the engine is running.

Possible Symptoms:
Check the engine light will illuminate.

Battery light may illuminate.

Vehicle may not shift properly or decrease in fuel economy

When is the Code Detected?


The code will set when the voltage level goes below 10.0 volts for more than 60 seconds while the

engine is running

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Fault code: P0563


Fault Code Definition:

P0563 Description:
The ECM receives power from the battery even when the vehicle is turned off. This permits data storage

and other essential functions. A vehicle will store this fault code when the ECM detects a voltage reading

which s out of range from what is expected

Possible Symptoms:
The battery light may come on, the engine could stall while idling, automatic transmission may not

function properly

When is the Code Detected?


vehicle will store this fault code when the ECM detects a voltage reading which s out of range from what is

expected.

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Fault code: P2503


Fault Code Definition:

P2503 Description:
The DTC indicates that the powertrain control module (PCM) has detected that the charging system

is no longer producing the correct voltage to sufficiently charge the battery

Possible Symptoms:
Vehicle dies while driving, vehicle fails to start, vehicle shifts abnormally, vehicle has multiple unrelated

warning lights illuminated, the red battery light is illuminated.

When is the Code Detected?


When the charging system is no longer producing the correct voltage to sufficiently charge the battery.

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Fault code: P0622


Fault Code Definition:

P0622 Description:
When the PCM logs a P0622 trouble code, its because it detected a problem with the generator field control.

The PCM uses the generator turn-on signal circuit to manage the generator

Possible Symptoms:
The engine light comes on, the battery could discharge, acceleration might become difficult

Possible causes:
Battery charge issue.

A malfunctioning generator.

A generator circuit that is suffering from a faulty electrical connection

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45. Looking at the alternator oscilloscope waveforms below from two (2) different vehicles, what do they show
about the alternators being tested?

A B
Alternator A: Alternator B:
Good AC generator under full load Shorted diode and/or stator winding under full
loadrrrrrrrrrrrrrrrrrrrrrrrrrrrr

46. Using the diagnostic scan tool data below, answer the following questions?

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1 What is the charging system target?


13.65v

2 What is the battery voltage?


13.53

3 What is Battery temperature? (Convert this to Celsius)


27.778 degree Celsius

4 What is the Engine RPM?


736 RPM

5 What is the vehicle speed of this vehicle at the time of testing?


0.0 MPH

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47. Using the diagnostic flow chart below, answer the following questions

1 Using the diagnostic flow chart, what should be checked first on this vehicle?
Check if charge bulb comes on.

2 What does the charge bulb (warning light) indicate?


Charge bulb warning light indicates problem with the alternator

3 What should you check if the charge bulb (warning light) remains ON when the engine is idling?
Check or replace fan belt.

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Check generator.

Check S or BAT terminal for improper contact.

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AURETR029 Diagnose and repair charging systems

48. What five (5) steps should you follow while inspecting a charging system?

1 Inspect the battery. It might be necessary to charge the battery to restore it to a fully charged state. If
the

battery cannot be charged it must be replaced. Make sure that the posts and cable clamps are clean
and

tight, because a bad connection can cause reduced current flow.

2 Inspect all system wiring and connections. Many systems contain fusible links or maxi-fuses to protect

against overloads; check them

3 Inspect the generator and regulator mountings for loose or missing bolts. Replace or tighten as
needed.

most generators and regulators complete their ground through their mounting. If the mountings are not

clean and tight, a high resistant ground will result.

4 Inspect the AC generator drive belt. Loose belts are major source of charging problems

5 Before adjusting belt tension, check for proper pulley alignment.

Multiple Choice question. Selected the correct answer.


49. What type of test equipment is needed to perform a charging system current output test?

A. An ammeter.
B. A voltmeter.
C. An oscilloscope.
D. A VAT with a carbon pile.

Multiple Choice question. Selected the correct answer.

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AURETR029 Diagnose and repair charging systems

50. A technician connects the red lead of a voltmeter to the B+ terminal of the alternator and the black lead to the
battery positive. He starts the engine and turns on the headlights and all the electrical accessories. What is
the technician measuring?

A. Resistance in the positive side charging system cables.


B. Diode leakage.
C. Charging voltage.
D. Charging current.

Multiple Choice question. Selected the correct answer.


51. When checking the alternator output using an oscilloscope, the current pattern resembles?

A. The rounded tops of a picket fence.


B. A square sine-wave pattern.
C. A square wave.
D. A sawtooth wave.

Multiple Choice question. Selected the correct answer.


52. A voltage drop over ______ volt(s) indicates high resistance in either the circuit or ground wiring of the
charging system.

1 0.1.
2 0.2.
3 0.5.
4 1.0.

53. Explain how to carry out a ‘No Load’ voltage output test?
To carry out a ‘No load’ voltage output test, start the engine and run it at the suggested rpm for this test

(usually 1,500 rpm). With no electrical load, the voltage reading should be about 2 volts higher than the open

circuit voltage.

54. Explain how to carry out a voltage output test with the charging system under load?
Increase the engine speed to about 2,000 rpm and turn on the headlights and other high currentaccessories.

The voltage output while under heavy load should be about 0.5 volt above the battery’sopen circuit voltage
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AURETR029 Diagnose and repair charging systems

55. Explain how to carry out a ‘Current’ output test on a charging system?
A VAT can quickly check the amperage output. With the tester connected to the system the engine is run at a

moderate speed (2,500 rpm) and the carbon pile adjusted to obtain maximum current output.The reading is

compared against the rated output.

56. What should you follow when removing and refitting the alternator assembly?
Follow service manual procedures when removing and installing an AC generator. Remember

improper connections to an AC generator can destroy it.

57. Before carrying out any repairs to the charging system, what should be done first?
Before carrying out any repairs to the charging system, what should be done first

Before carrying out any repair to the charging system get to the root of the trouble the first.

58. Describe the general procedure for removing and replacing the alternator.

Removal:
1 Park the car on an even surface level.

2 Disconnect the battery.

3 Remove the main power cable from the alternator.

4 Release the safety clip connecting the wiring harness.

5 Remove the belt from the pulley.

6 Loosen the bolts on the alternator if there is no auto-tensioner.

7 Remove the alternator from the engine bay.

8 Compare the new alternator to the old one.

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AURETR029 Diagnose and repair charging systems

Installing:
1 Slide the new alternator into place.

2 Insert the mounting bolts.

3 Run the belt over the new alternator pulley.

4 Apply tension to the alternator with a pry bar if necessary.

5 Tighten the bolts and the belt.

6 Connect the power cables and monitor harness.

7 Connect the safety clip connecting the wiring harness

8 Apply tension to the alternator with a pry bar if necessary.

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AURETR029 Diagnose and repair charging systems

59. After completing repairs on a vehicle, why must you retest the charging system?
After completing repairs on a vehicle one must retest the charging system because Once a customer drives

away with the assurance that the problem is solved, another case of a dead battery is very costly—both in

terms of a free service call and a damaged reputation.

60. What is the correct procedure for clearing charging system DTC’s?
Connect the techstream to the DLC3

Turn the ignition switch to on.

Turn the techstream on.

Enter the following menus: Powertrain/ Engine and ECT/ Clear DTCs

61. What could occur to the alternator if the wiring connectors were incorrectly installed?
Improper connections to an Alternator can destroy it.

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