Section 12 (Starting/Charging Systems (H4SO)): Generator: Assembly

WARNING: This page is about a different car, the 2006 Subaru Outback and 2006 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.

Assemble in the reverse order of disassembly.

Pull-out of the brush
Before assembling, press the brush down into the brush holder, then fix the brush in that position by inserting a [1 mm (0.08 in) dia., 40 to 50 mm (1.6 to 2.0 in) long] wire through the hole as shown in the figure.

CAUTION: After re-assembling, remove the wire.

Fig 1: Inserting Wire Through Hole
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.
Use a press to install the bearings (rear side) to the rotor shaft.
Heat the bearing box in rear cover [50 to 60°C (122 to 140°F)], and then press the rear bearing into rear cover.
CAUTION: Do not apply grease to the rear bearings. If there is any oil on the bearing box, remove it completely.
After re-assembling, manually turn the pulley to check that the rotor rotates smoothly.