Section 14 (Starting/Charging Systems (H4SO)): Generator: Disassembly

WARNING: This page is about a different car, the 2005 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Remove the four through-bolts.

Fig 1: Removing Bolts
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Heat the portion (A) of rear cover to 50°C (122°F) with heater drier.

Fig 2: Heating Portion Of Rear Cover
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Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Tip Of Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
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Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut Using Tool
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CAUTION: When holding the rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of vise to prevent rotor from damage.

Fig 5: Identifying Rotor
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Remove the ball bearing as follows.
1. Remove the bolt, and then remove the bearing retainer.
  
  Fig 6: Removing Bearing Retainer
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2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
  
  Fig 7: Installing Appropriate Tool
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3. Push the ball bearing off the front cover using a press.
Remove the bearing from rotor using a bearing puller.

Fig 8: Removing Bearing From Rotor Using Bearing Puller
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Unsolder connection between rectifier and stator coil to remove the stator coil.
CAUTION: Do not allow the 180 - 270 W solding bit to contact the terminals for more than 5 seconds at a time because the rectifier cannot withstand heat very well.

Fig 9: Removing Stator Coil
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Remove the IC regulator as follows.
1. Remove the screws which secure IC regulator to rear cover.
  
  Fig 10: Removing Screws Which Secure IC Regulator To Rear Cover
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2. Unsolder the connection between IC regulator and rectifier to remove the IC regulator.
  
  Fig 11: Unsoldering Connection Between IC Regulator
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Remove the brush as follows.
1. Remove cover A.
  
  Fig 12: Identifying Cover
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2. Remove the cover B.
  
  Fig 13: Removing Cover
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3. Separate the brush from connection to remove.
  
  Fig 14: Separating Brush From Connection
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Remove the rectifier as follows.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Locating Bolt
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2. Remove the cover of terminal B.
  
  Fig 16: Removing Cover Of Terminal B
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3. Remove the nut of terminal B, and then remove the rectifier.
  
  Fig 17: Locating Terminal Nut
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