Starting System & Charging System (H4SO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Identifying Through-Bolts
Courtesy of SUBARU OF AMERICA, INC.
Use a drier to heat the rear cover (A) portion to 50°C (122°F).

Fig 2: Applying Heat To Portion Of Rear Cover
Courtesy of SUBARU OF AMERICA, INC.
Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Separate these to disassemble.

Fig 3: Inserting Screwdriver Into Gap Between Stator Core And Front Cover
Courtesy of SUBARU OF AMERICA, INC.
Using a vise, support the rotor and remove the pulley bolt.

Fig 4: Removing Pulley Bolt
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Insert the aluminum plate or wood piece into the contact surface of the vise while support the rotor in the vise to prevent damaging the rotor.

Fig 5: Identifying Front Cover, Pulley, Nut And Rotor
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to remove the ball bearings.
1. Remove the bolt, and then detach the bearing retainer.
  
  Fig 6: Identifying Bearing Retainer Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Firmly install the appropriate tool (such as the right size of socket wrench) to the bearing inner race.
  
  Fig 7: Identifying Bearing Inner Race
  Courtesy of SUBARU OF AMERICA, INC.
3. Use the press to push the ball bearings from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Removing Bearings From Rotor Using Bearing Puller
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the connection between the rectifier and stator coil, then remove the stator coil.
CAUTION: Do not touch it with 180 to 270 W solder on its terminals for more than 5 seconds consecutively, because the rectifier cannot withstand so much heat.

Fig 9: Removing Stator Coil
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to remove the IC regulator.
1. Remove the screws which secure IC regulator to the rear cover.
  
  Fig 10: Identifying IC Regulator Screws
  Courtesy of SUBARU OF AMERICA, INC.
2. Disconnect the connection between the IC regulator and rectifier, then remove the IC regulator.
Fig 11: Disconnecting Connection Between IC Regulator And Rectifier
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to remove the brush.
1. Remove the cover A.
  
  Fig 12: Identifying Cover A
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover B.
  
  Fig 13: Identifying Cover B
  Courtesy of SUBARU OF AMERICA, INC.
3. Disconnect the connection and remove the brush.
Fig 14: Removing Brush From Connection
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to remove the rectifier.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Identifying Rectifier Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover on the terminal B.
  
  Fig 16: Identifying Cover Of Terminal B
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the nuts of the terminal B, then remove the rectifier.
Fig 17: Identifying Rectifier Terminal Nut B
Courtesy of SUBARU OF AMERICA, INC.