Subaru Legacy (2005 year). Manual - part 101

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STARTING/CHARGING SYSTEMS

Generator

• 3.0 L non-turbo model

C: DISASSEMBLY

1) Remove the four through-bolts.

2) Heat the portion (A) of rear cover to 50

°C

(122

°F) with a heater drier.

3) Insert the tip of a flat tip screwdriver into the gap
between stator core and front cover to disassem-
ble.

4) Hold the rotor with a vise and remove pulley nut.

CAUTION:
When holding the rotor with a vise, place alumi-
num plates or wooden pieces on the vise jaws 
to prevent rotor from damage.

5) Remove the ball bearing as follows.

(1) Remove the bolt, and then remove the bear-
ing retainer.

(A) Screwdriver

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(A)

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(A)

(A)

(A) Front cover

(B) Pulley

(C) Nut

(D) Rotor

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(A)

(B)

(C)

(D)

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STARTING/CHARGING SYSTEMS

Generator

(2) Firmly install an appropriate tool (such as a
fit socket wrench) to bearing inner race.

(3) Push the ball bearing off the front cover us-
ing a press.

6) Remove the bearing from rotor using a bearing
puller.

7) Unsolder the connection between rectifier and
stator coil to remove stator coil.

CAUTION:
Do not allow a 180 — 270 W soldering iron to 
contact the terminals for more than 5 seconds 
at once because the rectifier cannot withstand 
so much heat.

8) Remove the IC regulator as follows.

(1) Remove the screws which secure IC regula-
tor to rear cover.

(2) Unsolder the connection between IC regula-
tor and rectifier to remove IC regulator.

9) Remove the brush as follows.

(1) Remove the cover A.

(2) Remove the cover B.

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(A) Cover A

(A) Cover B

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(A)

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(A)

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STARTING/CHARGING SYSTEMS

Generator

(3) Separate the brush from connection to re-
move.

10) Remove the rectifier as follows.

(1) Remove the bolts which secure rectifier.

(2) Remove the cover of terminal B.

(3) Remove the nut of terminal B, and then re-
move the rectifier.

D: ASSEMBLY

Assemble in the reverse order of disassembly.
1) Pulling up brush
Before assembling, press the brush down into
brush holder, and then fix them in that position by
passing 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:
Be sure to remove the wire after reassembly.

2) Install the ball bearing.

(1) Set the ball bearing on the front cover, and
then securely install an appropriate tool (such as
a fit socket wrench) to the bearing outer race.
(2) Press the ball bearing into the specified po-
sition using a press.
(3) Install the bearing retainer.

3) Press the bearing (rear side) into the rotor shaft
using a press to install.
4) 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:
Grease should not be applied to rear bearing. 
Remove the oil completely if it is found on bear-
ing box.
5) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.

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(A) Wire

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(A)

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STARTING/CHARGING SYSTEMS

Generator

E: INSPECTION

1. DIODE

CAUTION:
Never use a mega tester (designed for reading 
high voltage) or any other similar instrument 
for this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
positive side heat sink. The positive diode is in
good condition if resistance is 1 

Ω or less only in the

direction from the diode lead to heat sink.

2) Checking negative diode
Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
good condition if resistance is 1 

Ω or less only in the

direction from the heat sink to diode lead.

2. ROTOR

1) Slip ring surface
Inspect the slip rings for contamination or any
roughness on the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn, replace the rotor assembly.

Slip ring outer diameter:

Standard

22.7 mm (0.894 in)

Limit

22.1 mm (0.870 in)

3) Continuity test
Check the resistance between slip rings using cir-
cuit tester.
If the resistance is not within the standard, replace
the rotor assembly.

Resistance value:

Approx. 1.8 — 2.2 

Ω

4) Insulation test
Check the continuity between slip ring and rotor
core or shaft. If resistance is 1 

Ω or less, the rotor

coil is grounded, and so replace the rotor assem-
bly.

5) Ball bearing (rear side)
Check the rear ball bearing. Replace if it is noisy or
if the rotor does not turn smoothly.

(A) Diode lead

(B) Heat sink (positive side)

(A) Diode lead

(B) Heat sink (negative side)

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(B)

(A)

(A)

(B)

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