Generators & Regulators: Overhaul: Disassembly

1. Remove the 4 housing bolts. See Fig 1 .
CAUTION: DO NOT insert screwdriver(s) too deeply. If inserted too deep, damage to stator coil may occur. When heating rear bearing, DO NOT use a heat gun to prevent damage to the diode assembly.
2. Insert a flat screwdriver between front housing and stator core, pry downward. See Fig 2 . The rear housing may be difficult to remove because a ring is used to lock the outer race of the rear bearing. If necessary, heat the rear bearing area with a 200 watt soldering iron. See Fig 3 .
CAUTION: Use care not to damage rotor when securing in vise.
3. Secure rotor in a vise with pulley side up. Remove the pulley nut. See Fig 4 . Remove spring washer, pulley, and spacer. Remove generator front housing and 2 seals. Remove rotor from vise.
4. Remove brush holder screws, rectifier screws, and nut from the "B" terminal. Remove stator assembly from rear bracket and remove slinger from brush holder.
CAUTION: When soldering or unsoldering, make sure that heat from soldering iron is not transmitted to the diodes for a long period. Do not exert excessive force on the leads of the diodes.
5. When stator is to be removed, unsolder the 3 stator leads to the main diodes on the rectifier. See Fig 5 .
6. When separating rectifier from brush holder, unsolder the 2 plates soldered to the rectifier. See Fig 5 .

Fig 1: Removing & Installing Generator Housing Bolts

Courtesy of HYUNDAI MOTOR CO.

Fig 2: Separating Generator Housings

Courtesy of HYUNDAI MOTOR CO.

Fig 3: Heating Generator Rear Bearing

Courtesy of HYUNDAI MOTOR CO.

Fig 4: Removing & Installing Generator Pulley Nut

Courtesy of HYUNDAI MOTOR CO.

Fig 5: Soldering & Unsoldering Stator Connections

Courtesy of HYUNDAI MOTOR CO.