Alternator (FA20): Disassembly

REMOVE GENERATOR REAR END COVER

Remove the 4 through bolts.

Fig 1: Locating Generator Rear End Cover Mounting Bolts
Courtesy of SUBARU OF AMERICA, INC.

Using the heat gun, heat the generator rear end cover.

HEATING TEMPERATURE

Item	Temperature
Generator Rear End Cover	50 to 60°C (122 to 140°F)

Fig 2: Heating Generator Rear End Cover Using Heat Gun

Courtesy of SUBARU OF AMERICA, INC.

Insert the 2 screw drivers, remove the generator rear end cover as shown in the illustration.

Fig 3: Removing Generator Rear End Cover Using Screw Drivers
Courtesy of SUBARU OF AMERICA, INC.

REMOVE GENERATOR PULLEY
1. Mount the generator in a vise between aluminum plates.
  
  Fig 4: Identifying Generator Mounted In Vise Between Aluminum Plate
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the nut and generator pulley.
  
  Fig 5: Removing Nut And Generator Pulley
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR DRIVE END FRAME ASSEMBLY
1. Remove the generator drive end frame assembly from the generator rotor assembly.
  
  Fig 6: Identifying Generator Drive End Frame Assembly
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Mount the generator drive end frame assembly in a vise between aluminum plates.
2. Remove the 4 bolts and bearing retainer.
  
  Fig 7: Locating Generator Drive End Frame Bearing Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
3. Securely attach an appropriate tool (a socket wrench of the correct size, etc.) to the bearing inner race.
4. Use a press to push the wheel bearing out of the front cover.
  
  Fig 8: Identifying Wheel Bearing
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR ROTOR BEARING
1. Use a bearing puller to remove the bearing from the rotor.
  
  Fig 9: Removing Generator Rotor Bearing Using Bearing Puller
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 6 bolts and generator coil assembly.
  
  Fig 10: Locating Generator Coil Assembly Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 4 bolts and generator brush holder assembly.
  
  Fig 11: Locating Generator Brush Holder Assembly Mounting Bolts
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE BRUSH
1. Remove the cover A from the brush holder assembly.
  
  Fig 12: Identifying Brush Holder Assembly Cover A
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover B from the brush holder assembly.
  
  Fig 13: Identifying Brush Holder Assembly Cover B
  Courtesy of SUBARU OF AMERICA, INC.
3. Using a soldering iron, separate the 2 brushes from the brush holder assembly.
  
  Fig 14: Separating Brushes From Brush Holder Assembly Using Soldering Iron
  Courtesy of SUBARU OF AMERICA, INC.
REMOVE GENERATOR HOLDER WITH RECTIFIER
1. Remove the terminal cover.
  
  Fig 15: Locating Terminal Cover
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the nut and the terminal.
  
  Fig 16: Locating Generator Holder With Rectifier Nut
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the 3 bolts and the generator holder with rectifier.
  
  Fig 17: Locating Generator Holder With Rectifier Bolts
  Courtesy of SUBARU OF AMERICA, INC.