Charging Systems: General: Generator: Reassembly

Assemble brush, and solder pigtail so that wear limit line of brush projects 0.079-0.118 in (2-3 mm) out of brush holder.

Fig 1: Measuring Brush Projection
Courtesy of KIA MOTORS AMERICA, INC.
Assemble regulator, and solder with rectifier and stator leads.
NOTE: Disconnect quickly. If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat.

Fig 2: Soldering Rectifier And Stator Leads
Courtesy of KIA MOTORS AMERICA, INC.
Assemble rear bracket and stator.
Tighten screws holding rectifier and brush holder.
Tightening torque:

1.5~4.0 lb-ft (2.0~5.4 N.m, 0.2~0.55 kg-m)
Tighten B terminal nut and insulating bushing.

Fig 3: Assembling Rear Bracket And Stator
Courtesy of KIA MOTORS AMERICA, INC.
Assemble rear bearing and stopper spring.
NOTE: Make sure groove on bearing rim is facing slip ring side.

Fig 4: Assembling Rear Bearing And Stopper Spring
Courtesy of KIA MOTORS AMERICA, INC.
Assemble front bearing. Using a socket which exactly fits outer race of bearing, carefully push in front bearing. Use a hand press or a vise.
NOTE: Insert protective material in the jaws of the vise.

Fig 5: Assembling Front Bearing
Courtesy of KIA MOTORS AMERICA, INC.
Place rotor in a vise, assemble front housing and tighten locknut.
Tightening torque: 43~72 lb-ft (59~98 N.m)

Fig 6: Assembling Front Housing And Tightening Locknut
Courtesy of KIA MOTORS AMERICA, INC.
Assemble rear housing and tighten four cap screws.
Tightening torque: 2.1~4.7 lb-ft (2.9~6.4 N.m, 0.3~0.65 kg-m))

Fig 7: Assembling Rear Housing & Tightening Screws
Courtesy of KIA MOTORS AMERICA, INC.