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Home >> Suzuki >> 2004 >> Swift + >> Repair and Diagnosis >> External Pages >> Different car >> Section 36 (Battery, Charging System And Starting System) >> Repair Instructions >> Generator Overhaul >> Assembly Procedure
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Assembly Procedure

WARNING: This page is about a different car, the 2005 Suzuki Swift +, 2005 Pontiac Wave, and 2005 Chevrolet Aveo. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Generator Through-Bolts
    GM1241906Courtesy of GENERAL MOTORS CORP.
    CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.
  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).
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the generator through-bolts.

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

    5. Fig 2: View Of Generator Drive End And Drive End Bearing Nut
    GM1241907Courtesy of GENERAL MOTORS CORP.
  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. Fig 3: Removing Rectifier, Regulator, And Brush Hold Assembly Screws
    GM1241902Courtesy of GENERAL MOTORS CORP.
  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.
    12. Fig 4: View Of Stator Connections And Rectifier Bridge Terminals
    GM1241901Courtesy of GENERAL MOTORS CORP.
    NOTE: 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.
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