Starting System & Charging System (H4DO): Generator: Assembly

NOTE: After assembling, manually turn the pulley to check that the rotor rotates smoothly.

Use the following procedures to install the rectifier.
1. Remove old silicone grease on the mating surface of rear cover and rectifier and apply new silicone grease.
  CAUTION: Do not apply silicone grease to the attachment threads of rectifier.
2. Install the rectifier and secure it using bolts.
  Tightening torque:
  
  3.9 N.m (0.4 kgf-m, 2.9 ft-lb)
  
  Fig 1: Identifying Rectifier Bolts
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the nut on terminal B.
  Tightening torque:
  
  8.9 N.m (0.9 kgf-m, 6.6 ft-lb)
  
  Fig 2: Identifying Terminal Nut
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the cover on terminal B.
Fig 3: Identifying Terminal Cover
Courtesy of SUBARU OF AMERICA, INC.
Use the following procedures to install the brush.
1. Install the brush and connect the connection.
  
  Fig 4: Connecting Brush Connection
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the cover B.
  
  Fig 5: Identifying Brush Cover B
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the cover A.
Fig 6: Identifying Brush Cover A
Courtesy of SUBARU OF AMERICA, INC.
Install the IC regulator, and secure it to the rear cover using the four screws.
Tightening torque:

T1: 2 N.m (0.2 kgf-m, 1.5 ft-lb)

T2: 3.9 N.m (0.4 kgf-m, 2.9 ft-lb)

Fig 7: Identifying IC Regulator Screws
Courtesy of SUBARU OF AMERICA, INC.
Install the stator coil, and secure it together with the rectifier using six bolts.
Tightening torque:

2 N.m (0.2 kgf-m, 1.5 ft-lb)

Fig 8: Identifying Stator Coil Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the ball bearings.
1. Set the ball bearings in the front cover, then securely install an appropriate tool (such as a socket wrench of proper size) to the bearing outer race.
2. Using a press to press the ball bearings into the specified location.
3. Install the bearing retainer.
Tightening torque:

3.9 N.m (0.4 kgf-m, 2.9 ft-lb)

Fig 9: Identifying Bearing Retainer Screws
Courtesy of SUBARU OF AMERICA, INC.
Use a press to install the bearings to the rotor shaft.
Install the rotor to the front cover, and install the pulley holding the rotor using a vise.
CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Tightening torque:

108 N.m (11.0 kgf-m, 79.8 ft-lb)

Fig 10: Installing Pulley
Courtesy of SUBARU OF AMERICA, INC.

Fig 11: Identifying Pulley, Front Cover And Rotor
Courtesy of SUBARU OF AMERICA, INC.
Press the brush into the brush holder, then fix the brush in that position by inserting a [1 mm (0.0394 in) dia., 40 - 50 mm (1.5748 - 1.9685 in) long] wire through the hole as shown in the figure.

Fig 12: Inserting Wire To Fix Brush
Courtesy of SUBARU OF AMERICA, INC.
Heat the bearing box in rear cover at 50 to 60°C (122 to 140°F), and then press the bearing into rear cover.
CAUTION: Do not apply grease to the bearings. If there is any oil on the bearing box, remove it completely.
Remove the wire.

Fig 13: Wire In Brush
Courtesy of SUBARU OF AMERICA, INC.
Install the four bolts.
Tightening torque:

4.4 N.m (0.4 kgf-m, 3.2 ft-lb)

Fig 14: Identifying Generator Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the cap to the generator.

Fig 15: Identifying Generator Cap
Courtesy of SUBARU OF AMERICA, INC.