Generator 37300-03300 LRA03539 2606900 89215522, 28-6811 suitable for modern 1.2L i10 i20

Pre-installation Preparation

• Park the vehicle on a flat surface, pull the handbrake tightly and turn off the engine. Wait for the engine to cool down to avoid being scalded by high-temperature components. Prepare tools such as socket wrenches, torque wrenches, insulated gloves, and safety goggles. If bolts are rusted, prepare rust remover in advance.

• Open the hood, locate the battery and disconnect the negative cable. Wrap the negative terminal with insulating tape and wait for a few minutes to allow the capacitor to discharge, preventing short circuits or electric shock risks during subsequent operations. At the same time, clean the dust, oil, and debris at the generator installation position to ensure the installation contact surface is clean and avoid affecting installation stability.

Placing the New Generator

• Carefully place the new generator in the installation position of the engine compartment and align it with the mounting holes of the fixing bolts. This step requires gentle handling to avoid colliding with the generator housing and surrounding components such as oil pipes and coolant pipes, preventing component damage or fluid leakage.

Preliminary Fixation of the Generator

• Use a socket wrench to screw the generator's fixing bolts (usually 2-3) into the aligned holes. Tighten them manually initially without fully securing them in one go, leaving room for subsequent adjustments. Pay attention to distinguishing the position and length of the bolts to avoid incorrect installation. If there are matching washers, assemble them in their original positions.

Installing the Drive Belt

• According to the original winding path of the belt, sequentially install the drive belt on the crankshaft pulley, water pump pulley, and generator pulley. Then find the belt tensioner, use a wrench of appropriate size to turn the tensioner adjustment hole, or adjust the belt tension through the generator's adjustment bolt. It is appropriate to apply a pressure of about 10kg to the middle of the belt, with a deflection of 8-12mm. This avoids belt slipping due to being too loose and bearing damage due to being too tight.

Connecting Electrical Circuits

• First, locate the generator's B+ terminal (main power terminal), connect the thick main power cable to this terminal, and tighten the fixing nut with a wrench. Then find the excitation signal connector, gently insert it aligning with the buckle position to ensure the buckle is firmly locked. Do not pull the wires to avoid damaging the wiring harness. Check the terminals during wiring to avoid incorrect connection leading to electrical system failures.

Tightening and Final Inspection

• Use a torque wrench to fully tighten the generator's fixing bolts according to the standard torque specified in the vehicle maintenance manual. Then remove the insulating tape from the battery's negative terminal, reconnect the battery negative pole and tighten the fixing nut.

Trial Operation and Testing

• Start the engine and observe whether the charging indicator light on the instrument panel turns off. If it turns off, it indicates that the generator is initially working normally. You can also use a multimeter to measure the generator output voltage; the normal range is usually 13.5-14.5V. Let the engine idle for 3-5 minutes, pay attention to any abnormal noise or vibration around the generator. Confirm there are no issues, and the installation is completed.

1. Safe Operation to Eliminate Electrical and Physical Risks

• Disconnect the battery negative terminal throughout the disassembly and assembly process, and wrap the terminal with insulating tape. Reconnect it only after all circuits are fully connected to prevent short circuits that could burn core components such as the ECU and generator regulator. Wear insulated gloves and safety goggles during operation to avoid electric shock, or scratches and scalds from sharp or high-temperature parts in the engine compartment.

• Use insulated tools that match the bolt specifications. Do not use brute force on rusted bolts—spray rust remover and let it stand for 10-15 minutes before operation to prevent bolt stripping or generator housing damage. Meanwhile, avoid oil pipes and coolant pipes in the engine compartment to prevent leakage due to collision.

2. Accessory Compatibility to Ensure Core Quality and Compatibility

• The new generator must be accurately matched to the vehicle’s specific model and engine type. Verify key dimensions such as the number of pulley grooves, mounting hole positions, and terminal types (e.g., B+ terminal specifications) to ensure consistency with the old generator. Prioritize Hyundai original factory or officially authorized accessories.

• Prohibit the use of low-quality aftermarket accessories. Such accessories have insufficient precision in internal components, leading to unstable power generation efficiency. They may also damage the vehicle’s electrical system (e.g., on-board electrical appliances, circuit boards) due to abnormal voltage output, increasing subsequent maintenance costs.

3. Installation Accuracy to Guarantee Operational Stability

• Thoroughly clean the generator’s mounting surface and bolt holes of dust, oil, and debris before installation to ensure tight contact between surfaces. This avoids generator vibration or resonance during vehicle operation. If there are original washers or spacers, assemble them in their original positions without omission or misalignment.

• Belt tension adjustment is critical: apply a pressure of approximately 10kg to the middle of the belt, with a normal deflection of 8-12mm. An overly loose belt may slip and cause insufficient power generation, while an overly tight belt will increase the load on the generator bearings and engine accessories, shortening their service life. Additionally, ensure the generator pulley is strictly aligned with the crankshaft and water pump pulleys, with a deviation not exceeding 1mm—otherwise, belt wear will accelerate.

• Tighten the fixing bolts to the standard torque specified in the maintenance manual (25-35N・m for most Hyundai models, subject to specific vehicle specifications) using a torque wrench. Avoid bolt loosening or housing deformation caused by over-tightening.

4. Electrical Connection to Avoid Circuit Failures

• Clearly distinguish terminals during wiring: the B+ terminal connects to the main power cable (thick wire), and the excitation signal terminal connects to the corresponding connector. Never misconnect or reverse the connections. After wiring, tighten the terminal nuts, check that the connector buckles are fully locked, and ensure the wiring harness is free of tension or distortion. Verify the integrity of the joint sealing rings to prevent short circuits caused by water ingress or poor contact.

• For some new Hyundai models (e.g., those equipped with intelligent charging systems), after replacing the generator, use a dedicated OBD diagnostic tool for initialization matching and input the generator parameters. This ensures coordinated operation with the vehicle’s electrical system—failure to do so may result in abnormal charging.

References：

Automotive Repair Teaching Materials

• For example, the "Automotive Generator Disassembly and Assembly Teaching Courseware" in Renren Document Library covers not only general tool preparation and safety operation specifications for generator disassembly and assembly but also detailed breakdowns of disassembly and installation steps. This content is equally applicable to the installation of 12V generators for Hyundai vehicles.

Professional Automotive Repair Platforms

• Taking Qiche Dashi (Car Master) as an example, this platform has published content on generator-related installation operations and precautions for Hyundai models (such as Hyundai Elantra). Summarized based on extensive practical maintenance experience with Hyundai vehicles, this content is suitable for daily maintenance scenarios and can provide practical references for the installation of 12V generators for Hyundai vehicles.

Automotive Information Platforms

• Platforms like Autohome have released multiple general guides on automotive generator disassembly and assembly. The precautions involved, such as drive belt tension adjustment, bolt tightening requirements, and power disconnection, have universal guiding significance for the installation of 12V generators for Hyundai vehicles.

• In addition, PCauto also provides a summary of general steps for automotive generator installation, which can serve as a reference for related operations on Hyundai vehicles.