Alternator (Fa20): Reassembly

Install Generator Holder With Rectifier
1. Install the generator holder with rectifier with the 3 bolts.
  
  Fig 1: Locating Generator Holder With Rectifier With 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 Brushes
1. Using a soldering iron, install the 2 brushes to the brush holder assembly.
  
  Fig 4: Installing Brushes To Brush Holder Assembly
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the cover B to the brush holder assembly.
  
  Fig 5: Installing Cover B To Brush Holder Assembly
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the cover A to the brush holder assembly.
  
  Fig 6: Installing Cover A To Brush Holder Assembly
  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 With 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: Inserting Pin Into Generator Rear End Cover
  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 With Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Install Generator Rotor Bearing
1. Using a press, press in a new generator rotor bearing.
  
  Fig 10: Installing Generator Rotor Bearing
  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 With 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: Installing Generator Drive End Frame Assembly To Generator Rotor Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Install Generator Pulley
1. Mount the generator in a vise between aluminum plates.
  
  Fig 13: Mounting Generator Using Aluminum Plates
  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

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 15: Heating Generator Rear End Cover

Courtesy of SUBARU OF AMERICA, INC.

Install the generator rear end cover.
Pull out the pin of the generator rear end cover.
Install the 4 through bolts.
Standard value: T=4.4N.m {45kgf.cm} {3.2ft.lbf}

Fig 16: Locating Generator Rear End Cover Bolts
Courtesy of SUBARU OF AMERICA, INC.