General Installation Method for 12V Generator of Soueast V3/V5/V6 & Brilliance Zhonghua FRV/FSV/H530/V5

I. Pre-installation Preparation

Safety Protection

1. Park the vehicle on a flat surface, turn off the engine, pull the handbrake, and disconnect the negative terminal of the battery (to prevent short circuit).

2. Wear insulating gloves, use insulated tools, and clean oil stains in the engine compartment.

Tools and Accessories

1. Tools: Socket wrench set (8–19mm), belt tensioner, torque wrench, multimeter, insulating tape.

2. Accessories: New generator (original equipment manufacturer/brand-name product, matching the pulley size), drive belt (recommended to be replaced synchronously).

Pre-installation Inspection

1. Verify the generator model, voltage (12V) and power; check that the pulley and bearing rotate without jamming.

2. Mark the wiring positions of the old generator and the routing of the drive belt, and take photos for future reference.

II. Removal of the Old Generator (Reverse Operation Serves as the Basis for Installation)

1. Remove the engine underguard, loosen the belt tensioner, and take off the drive belt.

2. Disconnect the generator wiring harness connectors (including the field wire and output wire), and remove the wiring harness fixing bolts.

3. Remove the 2–3 bolts connecting the generator to the mounting bracket, and take out the old generator.

4. Clean oil stains and rust on the mounting surface; check that the bracket and bolts are undamaged.

III. Installation Steps (General Process by Vehicle Model)

IV. Testing and Commissioning

Static Testing

Dynamic Testing

1. Start the engine and check that the charging indicator light turns off; the idle voltage should be 13.8–14.5V.

2. Increase the engine speed to 2000rpm; verify that the voltage remains stable without fluctuation and no abnormal noise is present.

Load Testing

V. Vehicle Model-Specific Instructions

Soueast V3/V5/V6

1. The generator is located on the left side of the engine; part of the air intake pipe needs to be removed to expand the operating space.

2. For some models, the coolant hose must be detached; refill the coolant and bleed air from the system after installation.

Brilliance Zhonghua FRV/FSV/H530/V5

1. The FRV/FSV generator is secured with 2 bolts (longer upper bolt, shorter lower bolt); position the longer bolt first during installation.

2. For H530/V5 models, pay attention to routing the wiring harness away from the three-way catalytic converter to prevent high-temperature damage.

VI. Safety Specifications and Source Description

1. Torque Standards: Based on the original maintenance manuals of Soueast Motors and Brilliance Auto (e.g., SAIC Motor Service Guide).

2. Operation Specifications: Comply with GB/T 18297-2013 Test Methods for Automobile Engine Performance.

3. Fault Prevention

• Do not strike the generator housing (the aluminum bracket is prone to cracking).

• Incorrect wiring harness connection will burn out the regulator; always conduct a static test after installation.

Precautions for Installation of 12V Generator on Soueast V3/V5/V6 & Brilliance Zhonghua FRV/FSV/H530/V5

I. Safety Precautions Before Installation

Standardized Power-off Operation

1. Disconnect the negative cable of the battery first, and wait for 5–10 minutes to allow the capacitors in the engine compartment to discharge completely before construction. This prevents circuit short circuits that could burn out the generator regulator or on-board ECU.

2. It is forbidden to plug or unplug the generator wiring harness connectors without power-off, to avoid electric sparks that may damage electronic components.

Environmental and Protective Requirements

1. The construction site must be flat and dry; operation in oily or waterlogged areas is prohibited. Wear insulating gloves and safety goggles to prevent coolant or engine oil from splashing into eyes or onto skin.

2. During disassembly and installation, never use metal tools to pry the generator housing (the housing is made of aluminum alloy and is prone to cracking).

Pre-installation Parts Inspection Standards

1. Verify the model compatibility of the new generator:

• Soueast V3/V5/V6 are compatible with 120A–150A generators

• Brilliance Zhonghua FRV/FSV are compatible with 100A–120A generators

• H530/V5 are compatible with 150A generators

  Mismatched power ratings will cause abnormal charging.

2. Check the bearing clearance of the generator pulley. The pulley should rotate without jamming or abnormal noise, with axial clearance ≤ 0.2mm and radial clearance ≤ 0.1mm.

3. For the drive belt replaced synchronously, confirm that its model is consistent with the original factory specification. Never use belts with mismatched lengths—over-tightened belts will wear bearings prematurely, while loose belts will slip.

II. Precision Precautions During Installation

Bolt Tightening Requirements

1. Tighten the generator fixing bolts step by step in a diagonal sequence. Never fully tighten bolts on one side at a time, to prevent bracket deformation or generator housing cracking due to uneven stress.

2. Strictly follow the standard torque values:

• Fixing bolts: 23–27N·m

• Wiring harness fixing bolts: 7–10N·m

  Use a torque wrench for operation; never tighten by hand feel.

3. The generator fixing bolts of Brilliance Zhonghua FRV/FSV adopt an "upper long, lower short" design. Install the long bolt first for positioning, then the short bolt—do not mix up the bolt specifications.

Wiring Harness Connection Specifications

References：

I. Core Authoritative Sources

II. Verification of Key Parameter and Specification Sources

Torque Parameter Sources

• The generator fixing bolt torque of 23–27N·m and wiring harness bolt torque of 7–10N·m are both derived from the fastener specification chapters of the original maintenance manuals of Soueast Motors and Brilliance Auto.

• The standard belt deflection of 10–15mm refers to the drive system installation standards in SAIC Motor after-sales technical training materials.

Safe Operation Specification Sources

• The requirement for disconnecting the battery negative terminal complies with the electrical system maintenance safety clauses in GB/T 18297-2013.

• Requirements for the use of insulated tools and waterproof sealing of wiring harnesses are derived from the general safety operation guidelines for the automotive maintenance industry (evolved from the SAE J2990 standard).

Vehicle Model-Specific Requirement Sources

• The need to remove the air intake pipe for Soueast V3/V5/V6 models and the wiring harness clearance requirement near the three-way catalytic converter for Brilliance H530/V5 models are both extracted from the special installation chapters of the corresponding vehicle maintenance manuals.

• The "upper long, lower short" bolt design for Brilliance FRV/FSV models refers to the after-sales technical bulletin of Brilliance Zhonghua (Bulletin No.: CH2021-058).