Alternator (FA20): Reassembly: Notes

INSTALL GENERATOR HOLDER WITH RECTIFIER
1. Install the generator holder with rectifier with the 3 bolts.
  
  Fig 1: Locating Generator Holder With Rectifier Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the terminal with the nut.
  Standard value: T=8.9N.m {91kgf.cm} {6.6ft.lbf}
  
  Fig 2: Locating Terminal With Nut
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the terminal cover.
  
  Fig 3: Locating Terminal Cover
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL BRUSH
1. Using a soldering iron, install the 2 brushes to the brush holder assembly.
  
  Fig 4: Installing Brushes To Brush Holder Assembly Using Soldering Iron
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the cover B to the brush holder assembly.
  
  Fig 5: Identifying Brush Holder Assembly Cover B
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the cover A to the brush holder assembly.
  
  Fig 6: Identifying Brush Holder Assembly Cover A
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR BRUSH HOLDER ASSEMBLY
1. Install the generator brush holder assembly with the 4 bolts.
  Standard value: Bolt A
  
  T=2.0N.m {20kgf.cm} {1.5ft.lbf}
  
  Bolt B
  
  T=3.9N.m {40kgf.cm} {2.9ft.lbf}
  
  Fig 7: Locating Generator Brush Holder Assembly Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. While pushing the 2 brushes into the generator rear end cover, insert a 1.0 mm {0.0394 in} pin into the generator rear end cover.
  CAUTION: Remove the pin after reassembling the generator.
  
  Fig 8: Identifying Pin
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR COIL ASSEMBLY
1. Install the generator coil assembly with the 6 bolts.
  Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf}
  
  Fig 9: Locating Generator Coil Assembly Mountings Bolts
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR ROTOR BEARING
1. Using a press, press in a new generator rotor bearing.
  
  Fig 10: Pressing Generator Rotor Bearing Using Press
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR DRIVE END FRAME BEARING
1. Set the wheel bearing onto the generator drive end frame and securely attach an appropriate tool (a socket wrench of the correct size, etc.) to the bearing outer race.
2. Using a press, press in a new generator drive end frame bearing.
3. Install the bearing retainer with the 4 screws.
  Standard value: T=3.9N.m {40kgf.cm} {2.9ft.lbf}
  
  Fig 11: Locating Bearing Retainer Mounting Screws
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR DRIVE END FRAME ASSEMBLY
1. Install the generator drive end frame assembly to the generator rotor assembly.
  
  Fig 12: Identifying Generator Drive End Frame Assembly
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR PULLEY
1. Mount the generator in a vise between aluminum plates.
  
  Fig 13: Identifying Generator Mounted In Vise Between Aluminum Plate
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the generator pulley with the nut.
  Standard value: T=108N.m {1101kgf.cm} {79.7ft.lbf}
  
  Fig 14: Installing Generator Pulley With Nut
  Courtesy of SUBARU OF AMERICA, INC.
INSTALL GENERATOR REAR END COVER
1. Using the heat gun, heat the generator rear end cover.
  Heating Temperature
  
  Fig 15: Heating Generator Rear End Cover Using Heat Gun
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the generator rear end cover.
3. Pull out the pin of the generator rear end cover.
4. Install the 4 through bolts.
  Standard value: T=4.4N.m {45kgf.cm} {3.2ft.lbf}
  
  Fig 16: Locating Generator Rear End Cover Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.