alternator 1002114523，100211167，100211-4450，1002114521 100211464，1002114650，1002114742，1012111040 101211-1043，101211140，101211148，1012113780 FOR Daihatsu

Pre-installation Preparation

1. First, disconnect the negative terminal of the car battery to avoid short circuits and component damage during installation. Meanwhile, clean oil stains and debris from the generator installation position in the engine compartment, and check if the mounting bracket is deformed or cracked.

2. Verify that the generator model is compatible with the vehicle. For used generators, check if the bearings run smoothly and if the terminal posts are oxidized. For Denso-supplied generators matched with Daihatsu, ensure the built-in plugs and insulation caps are intact; if the insulation caps are missing, protective measures for the terminals should be taken later.

Generator Positioning and Fixing

1. Lift the generator to the engine's mounting bracket, adjust its angle to align the mounting holes with those on the bracket. For some Daihatsu models, avoid components such as the air conditioning compressor and move the generator into place slowly.

2. Loosely tighten the upper and lower fixing bolts first (do not fully tighten) to facilitate subsequent adjustment of belt tension. Then, use a torque wrench to tighten the bolts according to the vehicle's specified torque—most passenger car generator fixing bolts require a torque of approximately 27–61N·m. For details, refer to the maintenance manual of the corresponding Daihatsu model.

3. If the mounting bracket needs adaptation or adjustment, ensure the homemade or adapted bracket is made of thick alloy/steel to prevent deformation or breakage during operation.

Drive Belt Assembly

1. Refer to the belt routing mark in the engine compartment to loop the drive belt over the generator pulley, crankshaft pulley, and idler pulley. Avoid incorrect routing, which may cause reverse rotation of the water pump and other faults.

2. Use a belt tensioning tool to adjust the belt tension—pressing the middle of the belt should allow it to sink 1–2 cm. After adjustment, recheck the generator's position to ensure no deviation, then fully tighten the previously loosened fixing bolts.

Precise Wiring Connection

• 3-pin type: One pin connects to the ignition indicator light, one to the power line controlled by the ignition switch, and one directly to the positive terminal of the battery.

• 4-pin type: A common wiring method is: one pin connects to the ignition indicator light, one is left unused, one connects to the power line controlled by the ignition switch, and one directly to the positive terminal of the battery.

Final Inspection and Debugging

1. Reconnect the negative terminal of the battery. Carefully check all bolts, belts, and wires to ensure no looseness and that no wires are tangled with moving parts.

2. Start the vehicle, observe whether the ignition indicator light on the instrument panel turns off normally, and check for abnormal noises during engine operation.

3. A multimeter can be used to measure the battery voltage. A normal voltage during idling is usually 13.5–14.5V, indicating the generator is functioning properly. If the voltage is abnormal or there are abnormal noises, stop the vehicle immediately to check the belt tension or wiring connections.

• The negative terminal of the battery must be disconnected throughout the entire process and reconnected only after installation is completed to eliminate the risk of short-circuit sparking.

• Wear gloves and goggles during operation, and keep away from high-temperature engine components (such as the exhaust pipe) to prevent scalds or oil stains on the skin.

• It is forbidden to touch both the positive and negative terminals of the generator with metal tools at the same time to avoid instantaneous short circuits that may burn out components.

• The generator model must be consistent with the original specifications of the Daihatsu vehicle. Focus on checking the voltage (12V), mounting hole positions, and pulley size to avoid failure in fixing or transmission.

• Before installation, check whether the generator bearings are smooth and whether the carbon brushes are excessively worn. For old generators, clean the oxide layer on the terminals; for new generators, ensure the insulation caps are intact.

• The drive belt must match the vehicle model specifications. Aging or cracked belts must be replaced to prevent breakage during operation.

• Fixing bolts must be tightened according to the torque specified for the vehicle model (most Daihatsu models require 27-61N·m). Loose bolts will cause the generator to vibrate and make abnormal noises, while over-tightening may damage the mounting bracket.

• Wiring connections must correspond to the functions of the interfaces; wrong connections or missing connections are not allowed. In particular, avoid directly connecting the ignition switch control line to the positive pole of the battery to prevent damage to electrical appliances.

• The adjustment of belt tension must be precise. Too loose a belt will easily slip, resulting in insufficient power generation; too tight a belt will accelerate the wear of the generator bearing and crankshaft bearing. The standard is that pressing the middle of the belt allows it to sink 1-2 cm.

• After starting the vehicle, first observe the ignition indicator light. If it stays on, stop the vehicle immediately to check the wiring connections or the excitation function of the generator.

• When measuring the battery voltage, the voltage at idle speed should be between 13.5-14.5V. A too-low voltage may be due to a slipping belt or wrong wiring, while a too-high voltage may indicate a fault in the generator regulator, which needs to be checked in time.

• If abnormal noises (such as belt squealing, bearing noise) occur during operation, stop the vehicle for inspection. It is forbidden to drive with faults to avoid damaging other engine components.

• After installation, ensure that all lines are kept away from moving engine parts (such as belts, fans) to prevent entanglement or abrasion of the insulation.

• The terminals should be coated with anti-rust agent and fitted with insulation caps. In the high-temperature and high-humidity environment of the engine compartment, additional insulation tape can be wrapped for enhanced protection.

• If you lack maintenance experience, it is recommended to refer to the maintenance manual of the corresponding Daihatsu model or ask professional technicians to operate to avoid secondary failures caused by improper self-installation.

References：

General Operating Guidelines for Automobile Generator Installation

Compatibility Characteristics of Small Passenger Car Generators

Basic Knowledge of Automotive Electrical Systems