SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Engine Electrical System Charging System
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REMOVAL AND INSTALLATION 
  1. Disconnect the negative terminal from the battery.

  1. Loosen the belt tension.

  1. Raise the vehicle.

  1. Remove the mud guard - RH

  1. Disconnect the generator B+ terminal wire and connector.

  1. Remove the belt and generator mounting bolt (2EA).

  1. Remove the generator assembly.

  1. Installation is the reverse order of removal.

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COMPONENTS 
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DISASSEMBLY 
  1. Remove the nut from the "B" terminal, and rear cover.

  1. When the stator is to be removed, unsolder the four stator leads to the main diodes on the rectifier.

    CAUTION
    1. When soldering or unsoldering, use care to make sure that heat of the soldering iron is not transmitted to the diodes for a long period.
    2. Use care that excessive force is not exerted on the leads of the diodes.
  1. Remove the stator assembly from the rear bracket.

  1. Remove the brush holder and the rectifier.

  1. Remove the four through bolts

  1. Insert a flat screwdriver between the front bracket and stator core, and pry downward.

    CAUTION
    1. Do not insert the screwdriver too deeply, as there is a danger of damaging the stator coil.
    2. The rear cover may be hard to remove because a ring is used to lock the outer race of the rear bearing. To facilitate removal of rear cover, heat just the bearing box' section with a 200-watt soldering iron. Do not use a heat gun, as it may damage the diode assembly.
  1. Secure the rotor in a vise with the pulley side up.

    CAUTION
    Be careful that the vise jaws do not damage the rotor.
  1. Remove the pulley nut, then remove the spring washer, then the pulley, and then the spacer.

  1. Remove the front bracket and seals.

  1. Remove the rotor from the vise.

  1. When separating the rectifier from the brush holder, unsolder the two plates soldered to the rectifier.

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INSPECTION 
ROTOR
  1. Check the rotor coil for continuity. Check to make sure that there is continuity between the slip rings. If resistance is extremely low, it means that there is a short. If there is no continuity or if there is a short circuit, replace the rotor assembly.

    RESISTANCE SPECIFICATION
    Resistance value: Approx. 2.7 O
  1. Check the rotor coil for ground. Check to make sure that there is no continuity between the slip ring and the core. If there is continuity, replace rotor assembly.

STATOR
  1. Make a continuity check on the stator coil. Check to make sure that there is continuity between the coil leads. If there is no continuity, replace stator assembly.

  1. Check the coil for grounding. Check to make sure that there is no continuity between the coil and the core. If there is continuity, replace the stator assembly.

RECTIFIERS
POSITIVE RECTIFIER TEST

Check for continuity between the positive rectifier and stator coil lead connection terminal with an ohmmeter. The ohmmeter should read continuity in only one direction. If there is continuity in both directions, a diode is shorted. Replace the rectifier assembly.

NEGATIVE RECTIFIER TEST

Check for continuity between the negative rectifier and the stator coil lead connection terminal. The ohmmeter should read continuity in only one direction. If there is continuity in both directions, a diode is shorted, and the rectifier assembly must be replaced.

DIODE TRIO TEST

Check the three diodes for continuity by connecting an ohmmeter to both ends of each diode. Each diode should have continuity in only one direction. If continuity is present in both directions, a diode is defective and the heatsink assembly must be replaced.

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REASSEMBLY 

Perform reassembly in the reverse procedure of disassembly. Pay attention to the following:

Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to lock the brushes. After the rotor has been installed, the wire can be removed.

INSTALLATION
  1. Position the generator and insert the support bolt. (Do not attach the nut.)

  1. Push the generator forward and determine how many spacers (thickness: 0.198mm) should be inserted between the front leg of the generator and the front case (space A in the illustration). (There should be enough spacers so that they do not fall out when you let go of them.)

  1. Insert the spacers (space A in the illustration), attach the nut, and complete the installation.