Hyundai Kona: Charging System / Alternator Repair procedures

Removal
1.
Turn ignition switch OFF and disconnect the battery negative (-) terminal.
2.
Disconnect the air compressor connector (A) and the alternator connector (B), and remove the cable (C) from alternator "B" terminal.

3.
Loose the alternator by loosening the mounting lower bolt (A) lightly, not completely, to remove the drive belt.

4.
Loosen the mounting bolts (A) and then, turn the adjusting bolt (B) clockwise to loosen tension.

5.
Remove the drive belt (A).

6.
Remove the alternator brace bracket assembly (B) after loosening the mounting bolt (A).

7.
Remove the alternator mounting low bolt (A), and then remove the alternator (B).

Installation
1.
Install in the reverse order of removal.
2.
Adjust the alternator belt tension after installation.
(Refer to Engine Mechanical System - "Drive Belt")
Alternator mounting upper bolt :
26.5 - 37.3 N.m (2.7 - 3.8 kgf.m, 19.5 - 27.5 Ib-ft)
Alternator mounting low bolt :
29.4 - 41.2 N.m (3.0 - 4.2 kgf.m, 21.7 - 30.4 Ib-ft)
Alternator brace mounting bolt :
24.3 - 26.9 N.m (2.48 - 2.74 kgf.m, 17.9 - 19.8 Ib-ft)
Disassembly
1.
Remove the alternator.
(Refer to Charging System - "Alternator")
2.
Remove the OAD (Overrunning Alternator Decoupler) cap (A).

  
When installing, replace with new OAD cap.
3.
Remove the OAD(Overrunning Alternator Decoupler) pulley (A) using the special tool.

4.
Remove the rear cover (A) after removing nuts.

5.
Remove the mounting bolts (A) and the regulator assembly (B).

6.
Remove the slip ring guide (A) after pulling it.

7.
Unsolder the 3 stator leads (A).

8.
Remove the 4 through bolts (A).

9.
Disconnect the rotor (A) and bracket (B).

Reassembly
[Rotor]
1.
Check that there is continuity between the slip rings (C).

2.
Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).
3.
If the rotor fails either continuity check, replace the alternator.
[Rotor]
1.
Check that there is continuity between each pair of leads (A).

2.
Check that there is no continuity between each lead and the coil core.
3.
If the coil fails either continuity check, replace the alternator.
Alternator Components and components location
Components 1. OAP (Overrunning Alternator Pulley) 2. Front bracket 3. Front bearing 4. Stator 5. Rotor 6. Rear Bearing 7. Rear Bracket 8. Bru ...

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