Alternator (Fa20): Disassembly

Remove Generator Rear End Cover

Fig 1: Locating Generator Rear End Cover Bolts

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Remove the 4 through bolts.

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

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

Fig 3: Removing Generator Rear End Cover
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Remove Generator Pulley
1. Mount the generator in a vise between aluminum plates.
  
  Fig 4: Mounting Generator Between Aluminum Plates
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2. Remove the nut and generator pulley.
  
  Fig 5: Removing Generator Pulley Nut
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Remove Generator Drive End Frame Assembly
1. Remove the generator drive end frame assembly from the generator rotor assembly.
  
  Fig 6: Removing Generator Drive End Frame Assembly From Generator Rotor Assembly
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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: Removing Bearing Retainer Bolts
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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: Pushing Wheel Bearing Out Of Front Cover
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Remove Generator Rotor Bearing
1. Use a bearing puller to remove the bearing from the rotor.
  
  Fig 9: Removing Generator Rotor Bearing
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Remove Generator Coil Assembly
1. Remove the 6 bolts and generator coil assembly.
  
  Fig 10: Locating Bolts And Generator Coil Assembly
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Remove Generator Brush Holder Assembly
1. Remove the 4 bolts and generator brush holder assembly.
  
  Fig 11: Locating Bolts And Generator Brush Holder Assembly
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Remove Brush
1. Remove the cover A from the brush holder assembly.
  
  Fig 12: Removing Cover A From Brush Holder Assembly
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2. Remove the cover B from the brush holder assembly.
  
  Fig 13: Removing Cover B From Brush Holder Assembly
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3. Using a soldering iron, separate the 2 brushes from the brush holder assembly.
  
  Fig 14: Separating Brushes From Brush Holder Assembly
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Remove Generator Holder With Rectifier
1. Remove the terminal cover.
  
  Fig 15: Locating Terminal Cover
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2. Remove the nut and the terminal.
  
  Fig 16: Locating Nut And Terminal
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3. Remove the 3 bolts and the generator holder with rectifier.
  
  Fig 17: Locating Bolts And Generator Holder With Rectifier
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