Alternator AC Generator 12180-SEN 213534 110620 CAL40248AS 1002111660

Pre-installation Preparation

• Tool and Accessory Preparation: Prepare tools including socket wrenches, torque wrenches, screwdrivers, rags, fine sandpaper, and conductive paste. Confirm that the model of the new 12V generator matches the corresponding Daihatsu vehicle model. Check that the generator housing is free of damage and the terminal posts are free of oxidation and rust. Meanwhile, prepare compatible fixing bolts and gaskets, and prioritize original specifications.

• Safe Power-off Operation: Park the vehicle on a flat road, pull the handbrake tightly, turn off the engine, and pull out the key. Be sure to disconnect the negative connection wire of the car battery to prevent short circuits during installation that may damage the generator or vehicle electronic components.

• Clean the Installation Area: If the old generator was just removed, wipe the generator mounting position on the engine with a rag to remove dust, oil, and debris. Ensure the mounting surface is flat and clean to avoid vibration or malfunctions caused by poor contact when the generator works later.

Core Installation Operations

• Precise Fixation of the Generator: Place the new generator stably on the mounting bracket and align it with the bolt holes on the bracket. Initially fix it with compatible bolts without fully tightening, leaving fine-tuning space. After confirming the generator position is correct and the pulley can be accurately aligned with the engine pulley, tighten the bolts with a torque wrench. The recommended tightening torque is generally 40-50N・m (specifically subject to the Daihatsu vehicle maintenance manual) to avoid damaging the mounting seat due to excessive torque or generator loosening due to insufficient torque.

• Standardized Wiring Connection: Distinguish interfaces such as the generator's power terminal (B+ terminal) and field terminal (F terminal) by referring to the wiring position of the old generator. Most 12V generators for Daihatsu vehicles are alternators: the B+ terminal should be connected to the battery positive electrode, the F terminal to the corresponding interface of the regulator, and the ground terminal (E or "-") to the vehicle body grounding point. If there is an oxide layer on the terminal posts, gently polish it off with fine sandpaper; apply a small amount of conductive paste if necessary to improve conductivity. Strictly prohibit reverse connection of positive and negative poles during wiring, and control the tightening torque of the wire harness nuts to approximately 12-15N・m to prevent damage to the terminal posts. Secure excess wire harnesses with cable ties, away from high-temperature areas of the engine.

• Install the Drive Belt: Adjust the belt tensioner, fit the drive belt over the generator pulley and the corresponding engine pulley, then fine-tune the tensioner to achieve moderate belt tension—pressing the belt with a hand should allow a 1-2 cm deflection. Excessively loose belt is prone to slipping, while overly tight belt will accelerate generator bearing wear.

Post-installation Inspection and Commissioning

• Recheck Wiring and Fixation: Reconnect the negative pole of the battery, and recheck whether the generator fixing bolts are loose, and whether all wire harness connectors are firmly connected without incorrect connection. Confirm the belt is properly installed without deviation or loosening.

• Start-up Test: Insert the key to start the engine and observe if the vehicle's charging indicator light turns off normally. A multimeter can be used to detect the generator output voltage—for a 12V generator, the normal output voltage during operation is usually between 13.5-14.5V. Meanwhile, pay attention to no abnormal noise during generator operation. If the charging indicator light remains on, the output voltage is abnormal, or there is abnormal noise, turn off the engine immediately to check for incorrect wiring, belt slipping, loose bolts, or other issues.

Pre-installation Preparation

• Ensure Power Off and Verify Accessories

  First, park the vehicle on a flat road and pull the handbrake tightly. After turning off the engine and pulling out the key, be sure to disconnect the negative wire of the car battery to prevent short circuits during installation that may damage the generator coil or on-board electronic components. At the same time, confirm that the model of the new generator matches the corresponding Daihatsu vehicle model. Check that the generator housing is free of damage, internal parts are not loose, and terminal posts are free of oxidation and rust. If there is oxidation, gently polish it off with fine sandpaper in advance.

• Clean Components and Prepare Auxiliary Materials

  Use a soft brush to clean components such as the generator's stator and rotor. The end cover and bearings can be cleaned with gasoline to avoid dust and oil affecting assembly accuracy. In addition, prepare compatible bolts and gaskets, as well as a small amount of conductive paste and insulating tape. Meanwhile, prepare tools such as a torque wrench and screwdrivers to facilitate standardized operations later.

In-installation Operation

• Standardize Generator Fixation

  When placing the generator on the mounting bracket, align it with the bolt holes on the bracket. It is recommended to tighten the bolts gradually, symmetrically, and evenly to avoid deviation of the installation center caused by fixing a single bolt first. Use original-specification bolts, and control the tightening torque appropriately—excessively loose bolts will cause the generator to vibrate during operation, while over-tightening may damage the mounting bracket or bolt threads. After installation, turn the pulley by hand to ensure there is no jamming.

• Precise Wiring to Prevent Misconnection

  Refer to the Daihatsu vehicle wiring diagram or the wiring marks on the old generator to distinguish terminal posts such as B+ (output wire), F (field wire), and E (ground wire). The B+ terminal post is connected to the battery positive electrode, the F terminal post to the corresponding interface of the regulator, and the E terminal post to the vehicle body ground or battery negative electrode. Strictly prohibit reverse connection of positive and negative poles during wiring. Control the tightening torque of the terminal post nuts to avoid ablation of the terminals and wire harnesses. If there are exposed parts of the wiring, wrap them with insulating tape.

• Carefully Assemble Auxiliary Components

  When installing the carbon brushes, fix the carbon brush lead connectors to the corresponding screws. After installing the carbon brush holder, place an insulating washer and a spring washer, then fix them with nuts. A multimeter can be used to detect the resistance between the F terminal and the housing to ensure it is infinite (non-conductive). When applying grease to the bearing cover, the amount should be about 2/3 of the bearing hole to ensure smooth operation.

References：

Automotive Maintenance Q&A and Encyclopedia Platforms

Universal Automotive Maintenance Technical Documents

Third-Party Automotive Maintenance Manual Platforms