Section 9 (Charging System - 1.8L): General: Generator: Reassembly

WARNING: This page is about a different car, the 2004 Kia Spectra. However, it is still accessible from the selected car via links, so may be relevant.

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.