Generators & Regulators: Overhaul Suzuki Vitara I

Disassembly (70A)

1. For easier reassembly, provide match marks (3) on both front housing (1) and rear housing (2) before separating them. (Scheme 12)
2. Remove housing bolts (1) from generator. (Scheme 13)
3. With lever (4) inserted between stator core (2) and front housing (3), separate generator into front (3) and rear (1) sides. (Scheme 14)
4. Loosen pulley nut (1) by using vise (4) and take off pulley.
5. Remove rotor (2) from front housing. (Scheme 15)
6. When removing front bearing, remove bearing retainer screws (2) and retainer. (Scheme 16)
7. When removing rear bearing (1), use oil hydraulic press "2". (Scheme 17)
8. Remove (3) screws (1) and generator "B" terminal nut (2). (Scheme 18)
9. Unsolder stator leads (1) and remove stator from rear housing and regulator assembly. (Scheme 19)
10. To remove brush, remove holder cover from brush holder and disconnect the brush wire from regulator terminal by using soldering iron. (Scheme 20)

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Reassembly (70A)

1. Assemble in the reverse order of disassembly. Be sure to install brushes (2) in the proper direction and solder brush wires and stator leads. (Scheme 19)and (Scheme 20).
2. Tighten generator pulley nut (1) to specifications. See «TORQUE SPECIFICATIONS»(ref-163058-S04317709932004061700000).
3. Push brushes into brush holder. Support brushes by inserting appropriate wire (2) from hole of rear housing (1). see scheme 31
4. After assembling generator, ensure that rotor turns smoothly.

Scheme 20

Reassembly (80A/105A)

1. If end housing bearing (1) is removed, install it.
2. Check end housing bearing (1) turns smoothly. (Scheme 22)
3. If stator (4) is removed, install stator (4) and tighten stud bolts (1).
4. If drive end bearing (3) is removed, install it.
5. Check drive end bearing (3) turns smoothly. If OK, install drive end bearing retaining plate (2). (Scheme 23)
6. Place drive end frame (2) on pulley, and install rotor (1) to drive end frame (2). (Scheme 24)
7. Install rear frame (1) to drive end frame (2). (Scheme 25)
8. Tighten 4 nuts to the specifications. See «TORQUE SPECIFICATIONS»(ref-163058-S04317709932004061700000).
9. Install pulley (1) and tighten pulley nut with holding shaft by using hexagonal box wrench (2) to the specifications. see scheme 36
10. Install 4 rubber insulators (1). see scheme 35
11. Install rectifier (1). see scheme 34
12. Install brush holder cover (1) to brush holder (2). (Scheme 26)
13. Place the IC regulator (1) together with the brush holder (2) horizontally on the rear end frame (3).
14. Install the 5 screws until there is a clearance of approximately.04" (1 mm) between the brush holder (2) and connector. (Scheme 27)
15. Install rear end cover (1) and terminal plate (4).
16. Install insulator (2) and tighten "B" terminal inner nut (3) to the specified torque. See «TORQUE SPECIFICATIONS»(ref-163058-S04317709932004061700000). (Scheme 28)
17. Ensure that rotor turns smoothly. see scheme 46

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28