Generators & Regulators: Overhaul: Disassembly

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.
1. Remove the 3 generator housing retaining bolts. Using a flat screwdriver(s) inserted between the front housing and the stator, pry downwards. See Fig 1 . 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 2 .
CAUTION: Use care not to damage rotor when securing in vise.
2. Secure rotor in a vise with pulley side up. Remove the pulley nut. See Fig 3 . Remove the spring washer, pulley and spacer. Remove the front housing and 2 seals. See Fig 4 . Remove rotor from the
3. Remove brush holder screws, rectifier screws, and nut from the generator "B" terminal. Remove stator from rear housing. Remove the slinger from the brush holder. See Fig 4 .
CAUTION: When soldering/unsoldering the rectifier, DO NOT heat the diodes for too long and DO NOT apply excessive force on the diodes.
4. With stator removed, unsolder the 3 stator leads from the main diodes. When separating the rectifier from the brush holder, unsolder the 2 plates that are soldered to the rectifier. See Fig 5 .

Fig 1: Separating Generator Housings

Courtesy of HYUNDAI MOTOR CO.

Fig 2: Heating Generator Rear Bearing

Courtesy of HYUNDAI MOTOR CO.

Fig 3: Removing & Installing Generator Pulley Nut

Courtesy of HYUNDAI MOTOR CO.

Fig 4: Exploded View Of Generator

Courtesy of HYUNDAI MOTOR CO.

Fig 5: Identifying Rectifier Solder Locations

Courtesy of HYUNDAI MOTOR CO.