Generator Overhaul 1.4L/1.5L SOHC and 1.4L/1.6L DOHC

1. Remove the generator. Refer to Generator Replacement .
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.




Notice: 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. Pry off the baffle.
6. Remove the rectifier/regulator/brush hold assembly screws.

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. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.



9. Retest by connecting the ohmmeter terminals in reverse.



10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining two diodes after the above procedure.

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. Remove the generator through-bolts.




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. 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. Test the rotor for open and short circuits. The reading should be 1.7 to 2.3 ohms, or the rotor should be replaced.



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. Remove the rotor assembly.



21. Remove the stator.



22. Test the stator for an open circuit using the ohmmeter.



23. Remove the ring in the slip ring end frame.

Caution: Refer to Safety Glasses Caution in the Preface section.




1. Install the new ring in the slip ring end frame.
2. Install the stator.
3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 in).

Notice: Refer to Fastener Notice in the Preface section.

4. Install the generator through-bolts.

Tighten
Tighten the generator through-bolts to 10 N·m (89 lb in).




5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.

Tighten
Tighten the generator drive and end bearing nut to 81 N·m (60 lb ft).

6. Install the generator. Refer to Generator Replacement .



7. Wield the brush holder terminal to the regulator terminal, if removed.
8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
9. Apply silicone grease between the bridge and the end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
11. Punch the new baffle with the pin into the brush.




Notice: Protect the diode in the rectifier bridge from excessive heat while welding. Overheating the diode will cause damage to the rectifier bridge.

12. Weld the connectors of the rectifier bridge.

Generator Overhaul 1.2L SOHC

1. Remove the generator. Refer to Generator Replacement .
2. Mark the generator housing for assembly.
3. Remove the front bracket and rear bracket.
4. Remove the generator through-bolts.



5. Pry the front housing downwards using a screwdriver.
6. Separate the front housing and rear housing.



7. Cover the rotor with the cloth.
8. Place the pulley upwards and carefully vise the rotor.
9. Remove the pulley nut.
10. Remove the pulley.



11. Remove the collar (large).
12. Remove the rotor from the front housing.
13. Remove the collar (small) from the rotor shaft.



14. Remove the support plate screws.
15. Remove the support plate.
16. Remove the front bearing using a press.



17. Remove the battery position terminal nut.
18. Remove the battery positive terminal washer.



19. Remove the stator assembly from the rear housing.
20. Remove the rectifier screws.
21. Remove the brush holder and regulator assembly screws.
22. Remove the stator assembly with the rectifier/brush holder/regulator.



23. Remove the rectifier/brush holder/regulator connections.

Notice: 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.

24. Remove the stator and rectifier connections.



25. Test the rotor for an open circuit by using the ohmmeter. Replace the rotor if necessary.



26. Test the rotor for a shorted circuit. The measured resistance should be around 2.9 ohms. Replace the rotor if not within the specification.



27. Test the stator for an open circuit by using the ohmmeter. Replace the stator if necessary.



28. Test the stator for a grounded circuit by using an ohmmeter. Replace the stator if necessary.



29. Inspect the rectifier, positive rectifier test.
30. Inspect for an open circuit at the stator coil lead terminals using an ohmmeter.
31. Replace the rectifier if necessary.



32. Inspect the rectifier, negative rectifier test.
33. Inspect for an open circuit at the stator coil lead terminals using an ohmmeter.
34. Replace the rectifier if necessary.



35. Inspect trio diodes for an open using an ohmmeter. Replace the trio diodes if necessary.



36. Inspect the brushes for wear.
37. If the brush wear exceeds the specified value (A), replace the brush. Brush Wear: Standard 18.5 mm (0.73 in) Limit 13.5 mm (0.53 in).

1. Install the stator/rectifier/brush housing assembly into the rear housing and inserting a small tool (2) into the housing to hold down the brushes (1).

Notice: Refer to Fastener Notice in the Preface section.




2. Install the stator bolts and nut and screws.

Tighten

•	Tighten the brush holder/regulator/rectifier screws to 12 N·m (106 lb in).

•	Tighten the battery positive terminal nut to 7 N·m (62 lb in).




3. Install the bearing to the housing and install the bearing plate screws.

Tighten
Tighten the front bearing plate screws to 8 N·m (71 lb in).




4. Install the front housing, and collars to the rotor.
5. Install the rotor assemblies to the rear housing.



6. Place the pulley upwards and carefully vise the rotor using a soft cloth.
7. Install the generator pulley and nut.

Tighten
Tighten the pulley nut to 110 N·m (81 lb ft).




8. Assemble the 2 halves of the generator and align to the marks, and install the generator housing through-bolts.

Tighten
Tighten the through-bolts to 10 N·m (89 lb in).

9. Install the generator. Refer to Generator Replacement .