Charging Systems: General: Generator: Disassembly

NOTE: Insert protective material in the jaws of the vise.

Remove four cap screws from rear housing.

Fig 1: Removing Four Cap Screws From Rear Housing
Courtesy of KIA MOTORS AMERICA, INC.
Use a 200-watt soldering iron to heat the rear of bearing box to allow the bearing to be removed from rear housing.
NOTE: If bearing box is not heated, bearing cannot be pulled out of rear housing. The rear bearing and rear housing fit together very tightly.

Fig 2: Heating Bearing Box
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Use a flat-blade screwdriver to separate front housing from stator.

Fig 3: Separating Front Housing From Stator
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Be careful not to lose the stopper spring that fits around the rear bearing.

Fig 4: Identifying Stopper Ring
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NOTE: Insert protective material in the jaws of the vise.
Place rotor in a vise and loosen locknut, then disassemble pulley, rotor, and front housing.

Fig 5: Loosening Locknut
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If necessary, remove front bearing using a socket and a hand press or vise.
Remove rear bearing with a bearing puller.

Fig 6: Removing Rear Bearing
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Remove B terminal nut and insulating bushing.
Remove five screws holding the rectifier and brush holder.

Fig 7: Removing Screws Holding The Rectifier And Brush Holder
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Separate rear bracket and stator.

Fig 8: Separating Rear Bracket And Stator
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Use a soldering iron to remove solder from rectifier and stator leads, and then remove IC regulator.
NOTE: Disconnect quickly. If soldering iron is used for more than 5 seconds, rectifier may be damaged by heat.

Fig 9: Removing Solder From Rectifier And Stator Leads
Courtesy of KIA MOTORS AMERICA, INC.
Replace brushes. Remove solder from pigtail, and then remove brush.

Fig 10: Replacing Brushes
Courtesy of KIA MOTORS AMERICA, INC.