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Charging Systems: Overhaul: Generator: Assembly

  1. Connect the brushes to the regulator. See Fig 1 . Install the brush springs and the brushes to the regulator so that the label on each brush is 2- 3 mm (0.008-0.012 in) from the rectifier.
  2. Solder the brush lead wires to the regulator terminals. See Figure . Install the brush lead wire cover. Connect the brush holder to the regulator. Install the regulator and the brush holder to the rear housing. See Figure .
  3. Install the rectifier to the rear housing. Install the stator to the rear housing. Secure the stator with the four retaining screws. See Figure .
  4. Solder the stator lead wires to the regulator terminals. See Figure . Remove the hole plug from the rear housing. Support the brushes with a wire inserted through the hole in the rear housing. See Fig 2 .
  5. Install the battery terminal retaining nut to the rear housing. Tighten the battery terminal retaining nut to specifications. See TORQUE SPECIFICATIONS  .
  6. Install the rear bearing to the rotor. Install the front bearing and the front bearing retainer to the front housing. Secure with 4 screws. Install the rotor with the spacer to the front housing.
  7. Place the front housing and the rotor into a vise, facing the drive pulley end up. Install the drive pulley and the drive pulley washer to the rotor. Secure the pulley with the retaining nut. Tighten the drive pulley retaining nut to specifications. See TORQUE SPECIFICATIONS  .
  8. Remove the front housing and the rotor from the vise. Using a heat gun, heat the rear housing to 50- 60°C (122-140°F). Align the generator housing match marks. See Figure . Install the front housing, with the drive pulley and rotor, to the stator coil and rear housing.
  9. Install the 4 front housing generator housing bolts. Tighten the generator housing bolts to specifications. See TORQUE SPECIFICATIONS  .
  10. Remove the brush support wire and install the hole plug into the rear housing. Make sure that the rotor rotates smoothly by turning the drive pulley. Install the generator to the vehicle. See GENERATOR  under REMOVAL & INSTALLATION.
Fig 1: Connecting Brushes To Regulator
G00369447Courtesy of GENERAL MOTORS CORP.
Fig 2: Supporting Brushes With Wire
G00369448Courtesy of GENERAL MOTORS CORP.
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