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

Remove the four through-bolts.

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

Fig 2: Heating Rear Cover Using Drier
Courtesy of SUBARU OF AMERICA, INC.
Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Flat Tip 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: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

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 Ball Bearing In Vise
  Courtesy of SUBARU OF AMERICA, INC.
2. Firmly attach an appropriate tool (such as a correct size 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 out from the front cover.
Using the bearing puller, remove the bearings from the rotor.

Fig 8: Pushing Ball Bearing Off Front Cover
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the connection between the rectifier and stator coil, then remove the stator coil.
CAUTION: The rectifier is easily damaged by heat. Do not allow a 180 - 270 W soldering iron to contact the terminals for 5 seconds or more at a time.

Fig 9: Disconnecting Connection Between Rectifier And Stator Coil
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to remove the IC regulator.
1. Remove the screws which secure the IC regulator to the rear cover.
  
  Fig 10: Identifying IC Regulator
  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.
Remove the rectifier as follows.
1. Remove the bolts which secure the rectifier.
  
  Fig 15: Locating Rectifier Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover on B terminal.
  
  Fig 16: Locating Cover Of Terminal B
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the nuts of B terminal, then remove the rectifier.
Fig 17: Locating Nut Of Terminal B
Courtesy of SUBARU OF AMERICA, INC.