Generator Disassembly and Assembly: Disassembly

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2008 Suzuki Reno, 2008 Suzuki Forenza, 2007 Suzuki Reno, 2007 Suzuki Forenza, and 2006 Suzuki Reno. However, it is still accessible from the selected car via links, so may be relevant.

Remove the generator. Refer to Generator Removal and Installation .
Mark a match line that cannot easily be removed on the end frame to make assembly easier.
Pry off the plastic cover to expose the stator connections.

Fig 1: Identifying Generator
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Remove the stator connections from the rectifier bridge terminals by cutting the wires.

Fig 2: Stator Connections On Rectifier Bridge Terminals
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Pry off the baffle.
Remove the rectifier/regulator/brush holder assembly screws.
Remove the brush holder assembly and the regulator.

Fig 3: Identifying Brush Holder Assembly And Regulator
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Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.

Fig 4: Testing Rectifier Bridge By Connecting Ohmmeter To Bridge And Heat Sink
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Retest by connecting the ohmmeter terminals in reverse.

Fig 5: Testing With Ohmmeter Terminals In Reverse
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Replace the rectifier bridge, if each reading is the same.
Test the remaining two diodes after the above procedure.
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.
See Fig 4.
Remove the generator through-bolts.

Fig 6: Identifying Generator With Through-Bolts Removed
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Move to the drive end of the generator and remove the drive end bearing nut.
Remove the pulley and the collars.

Fig 7: Removing/Installing Drive End Bearing Nut
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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.

Fig 8: Testing Rotor For Open Circuit
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Test the rotor for open and short circuits. The reading should be 1.7 - 2.3 Ω, or the rotor should be replaced.

Fig 9: Testing Rotor For Open And Short Circuits
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Remove the drive end frame from the shaft.
For vehicles with an internal generator fan, remove the drive end frame and the fan.

Fig 10: Identifying Drive End Frame
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Remove the rotor assembly.

Fig 11: Identifying Rotor Assembly
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Remove the stator.

Fig 12: Identifying Stator
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Test the stator for an open circuit using the ohmmeter.

Fig 13: Testing Stator For Open Circuit Using Ohmmeter
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Remove the ring in the slip ring end frame.

Fig 14: Identifying Ring In Slip Ring End Frame
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