Generator Disassembly And Assembly: Disassembly

WARNING: This page is about a different car, the 2008 Suzuki Grand Vitara, 2007 Suzuki Grand Vitara, and 2006 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Put match marks at 2 locations (A (front housing (1) and stator (2)) and B (rear housing (3) and stator (2))) as shown in figure so that any possible mistake can be avoided.

Fig 1: Aligning Match Marks On Generator Housing
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Loosen frame bolt (1).

Fig 2: Identifying Frame Bolts
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Remove front housing with rotor (1) from stator (2).

Fig 3: Identifying Rotor & Stator
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Hold rotor by using vise (2) and loosen pulley nut and then remove pulley (1).
CAUTION: When using vise, put clean cloth (3) and aluminum plate (5) between rotor (4) and vise (2) so as not to cause damage to rotor.

Fig 4: Loosening Pulley Nut
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If required, remove drive end bearing.
1. Loosen retainer screw (1) and then remove retainer.
  
  Fig 5: Identifying Retainer Screw
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2. Push out drive end bearing by using hydraulic press (1) and special tool.
  Special Tool
  1. 09943-88211
    
    Fig 6: Pushing Out Drive End Bearing Using Hydraulic Press & Special Tool
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If required, use bearing puller (2) to remove rear end bearing (1).

Fig 7: Identifying Bearing Puller & Rear End Bearing
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Loosen screw (1) and then remove stator (2) from rear housing.

Fig 8: Identifying Stator
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Remove cap (1).
Loosen "B" terminal nut and then remove insulator (2).

Fig 9: Identifying Insulator & Cap
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Loosen screw (1) and then regulator assembly (2).
Loosen screw (3) and then remove rectifier (4).

Fig 10: Identifying Regulator Assembly & Rectifier
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