Section 17 (Starting/Charging Systems (H4SO)): Generator: Disassembly

WARNING: This page is about a different car, the 2006 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.

Remove the four through-bolts.

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

Fig 2: Applying Heat To 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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(A) Screwdriver
Hold the rotor with a vise and remove pulley nut.

Fig 4: Holding Rotor With Vise
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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, Front Cover And Pulley
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Remove the ball bearing as follows.
1. Remove the bolt, and then remove the bearing retainer.
  
  Fig 6: Identifying Ball Bearing In Vise
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2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
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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: Pushing Ball Bearing Off Front Cover
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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: Unsoldering Connection Between Rectifier And 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: Identifying IC Regulator
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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 And Rectifier
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Remove the brush as follows.
1. Remove cover A.
  
  Fig 12: Identifying Cover A
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2. Remove the cover B.
  
  Fig 13: Identifying Cover B
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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 Rectifier Bolt
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2. Remove the cover of terminal B.
  
  Fig 16: Locating Cover Of Terminal B
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3. Remove the nut of terminal B, and then remove the rectifier.
  
  Fig 17: Locating Nut Of Terminal B
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