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Disassembly Procedure

    Fig 1: Removing Generator
    GM1241900Courtesy of GENERAL MOTORS CORP.
  1. Remove the generator. Refer to Generator Replacement (1.6L)  or Generator Replacement (1.8L/2.0L) .
  2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
  3. Pry off the plastic cover to expose the stator connections.
    4. Fig 2: View Of Stator Connections And Rectifier Bridge Terminals
    GM1241901Courtesy of GENERAL MOTORS CORP.
    NOTE: If the stator connections are welded in, use just enough heat to melt the lead. Avoid using to much heat as it can damage the diodes.
  4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
    5. Fig 3: View Of Stator And Components
    GM1241902Courtesy of GENERAL MOTORS CORP.
  5. Pry off the baffle.
  6. Remove the rectifier/regulator/brush holder assembly screws.
    7. IMPORTANT: If the brush can be reused, reassemble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.
  7. Remove the brush holder assembly and the regulator.
    8. Fig 4: Testing Rectifier Bridge Using Ohmmeter Terminals
    GM1241903Courtesy of GENERAL MOTORS CORP.
  8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
    9. Fig 5: Retesting Using Ohmmeter Terminals In Reverse
    GM1241904Courtesy of GENERAL MOTORS CORP.
  9. Retest by connecting the ohmmeter terminals in reverse.
    10. Fig 6: Testing Rectifier Bridge Using Ohmmeter Terminals
    GM1241903Courtesy of GENERAL MOTORS CORP.
  10. Replace the rectifier bridge, if each reading is the same.
  11. Test the remaining 2 diodes after the above procedure.
    12. IMPORTANT: Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.
  12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced.
    13. Fig 7: View Of Generator Through-Bolts
    GM1241906Courtesy of GENERAL MOTORS CORP.
  13. Remove the generator through-bolts.
    14. Fig 8: View Of Generator Drive End And Drive End Bearing Nut
    GM1241907Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The fastening torque of this nut is 81 N.m (60 lb ft) and may not normally be unfastened using hand strength.
  14. Move to the drive end of the generator and remove the drive end bearing nut.
  15. Remove the pulley and the collars.
    16. Fig 9: Testing Rotor For Open Circuit Using Ohmmeter
    GM1241908Courtesy of GENERAL MOTORS CORP.
  16. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced.
    17. Fig 10: Testing Rotor For Open And Short Circuits Using Ohmmeter
    GM1289364Courtesy of GENERAL MOTORS CORP.
  17. Test the rotor for open and short circuits. The reading should be 1.7-2.3 ohms, or the rotor should be replaced.
    18. Fig 11: View Of Drive End Frame
    GM1241909Courtesy of GENERAL MOTORS CORP.
  18. Remove the drive end frame from the shaft.
  19. For vehicles with an internal generator fan, remove the drive end frame and the fan.
    20. Fig 12: View Of Rotor Assembly
    GM1241910Courtesy of GENERAL MOTORS CORP.
  20. Remove the rotor assembly.
    21. Fig 13: View Of Stator
    GM1241911Courtesy of GENERAL MOTORS CORP.
  21. Remove the stator.
    22. Fig 14: Testing Stator For Open Circuit Using Ohmmeter
    GM1241912Courtesy of GENERAL MOTORS CORP.
  22. Test the stator for an open circuit using the ohmmeter.
    23. Fig 15: View Of Slip Ring End Frame Ring
    GM1241913Courtesy of GENERAL MOTORS CORP.
  23. Remove the ring in the slip ring end frame.
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