Generator & Regulators: Overhaul: Disassembly

CAUTION: When soldering/unsoldering the rectifier, DO NOT heat the diodes for too long and DO NOT apply excessive force on the diodes.
1. Remove nut from the "B" terminal, and rear cover. When stator is to be removed, unsolder the 4 stator leads-to-main diodes on rectifier. See Fig 1 .
2. Remove stator assembly from the rear generator housing.
3. Remove brush holder and rectifier.
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.
4. Remove the 4 through bolts. Using a flat screwdriver(s) inserted between the front housing and the stator, pry downwards. 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.
5. 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 seals. Remove rotor from vise.
6. When separating rectifier from brush holder, unsolder the 2 plates soldered to the rectifier. See Fig 5 .

Fig 1: Identifying Stator Solder Locations

Courtesy of HYUNDAI MOTOR CO.

Fig 2: Separating Generator Housings

Courtesy of HYUNDAI MOTOR CO.

Fig 3: Heating Generator Rear Cover

Courtesy of HYUNDAI MOTOR CO.

Fig 4: Removing & Installing Generator Pulley Nut

Courtesy of HYUNDAI MOTOR CO.

Fig 5: Identifying Rectifier Solder Locations

Courtesy of HYUNDAI MOTOR CO.