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HOMESERVICE MANUALSHYUNDAI2003XG350 BASEREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALCHARGING SYSTEMSGENERATORS & REGULATORSOVERHAULDISASSEMBLY
2003 Hyundai XG350 Base

Generators & Regulators: Overhaul: Disassembly

2003 Hyundai XG350 BaseSECTION Disassembly
  1. Remove the 4 housing bolts. See Fig 1 .
    2. CAUTION: DO NOT insert screwdriver(s) too deeply. If inserted too deep, damage to stator coil may occur. When heating rear bearing, DO NOT use a heat gun to prevent damage to the diode assembly.
  2. Insert a flat screwdriver between front housing and stator core, pry downward. See Fig 2 . The rear housing may be difficult to remove because a ring is used to lock the outer race of the rear bearing. If necessary, heat the rear bearing area with a 200 watt soldering iron. See Fig 3 .
    3. CAUTION: Use care not to damage rotor when securing in vise.
  3. Secure rotor in a vise with pulley side up. Remove the pulley nut. See Fig 4 . Remove spring washer, pulley, and spacer. Remove generator front housing and 2 seals. Remove rotor from vise.
  4. Remove brush holder screws, rectifier screws, and nut from the "B" terminal. Remove stator assembly from rear bracket and remove slinger from brush holder.
    5. CAUTION: When soldering or unsoldering, make sure that heat from soldering iron is not transmitted to the diodes for a long period. Do not exert excessive force on the leads of the diodes.
  5. When stator is to be removed, unsolder the 3 stator leads to the main diodes on the rectifier. See Fig 5 .
  6. When separating rectifier from brush holder, unsolder the 2 plates soldered to the rectifier. See Fig 5 .
Fig 1: Removing & Installing Generator Housing Bolts
G00330237Courtesy of HYUNDAI MOTOR CO.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.