2001 СУБАРУ ФОРЕСТЕР. Руководство по обслуживанию

GENERATOR

Starting/Charging Systems

3) Hold rotor with a vise and remove pulley nut.

B: INSTALLATION

S179008A11

Install in the reverse order of removal.

CAUTION:

Check and adjust V-belt tension. <Ref. to

ME(SOHC) -43, INSPECTION, V-belt.> and <Ref.

to ME(DOHC TURBO) -45, INSPECTION,

V-belt.>

CAUTION:

When holding rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of the vise to prevent rotor from damage.

C: DISASSEMBLY

S179008A06

50°C

1) Heat the portion (A) of rear cover to (122°F) with heater drier.

(A) Front bracket

(B) Pulley

(D) Rotor

4) Unsolder connection between rectifier and staВtor coil to remove stator coil.

CAUTION:

Finish the work rapidly (less than three secВonds) because the rectifier cannot withstand heat very well.

2) Remove the four through bolts. Then insert the tip of a flat-head screwdriver into the gap between the stator core and front bracket. Pry then apart to disassemble.

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GENERATOR

Starting/Charging Systems

5) Remove screws which secure IC regulator to rear cover, and unsolder connection between IC regulator and rectifier to remove IC regulator.

CAUTION:

Be sure to remove the wire after reassembly.

2) Heat the bearing box in the rear bracket [50 to 60°C (122 to 140°F)] and press the rear bearing into the rear bracket.

CAUTION:

Grease should not be applied for the rear bearВing. Remove oil completely if it is found on the bearing box.

3) After reassembly, turn the pulley by hand to check that the rotor turns smoothly.

6) Remove the brushes by unsoldering at the pigВtails.

E: INSPECTION

S179008A10

1. DIODE

S179008A1001

CAUTION:

Never use a megger tester (measuring use for high voltage) or any other similar measure for this test; otherwise, the diodes may be damВaged.

1) Checking positive diode Check for continuity between the diode lead and the positive side heat sink. The positive diode is in good condition if continuity (1 D. or less) exists only in the direction from the diode lead to the heat sink.

7) Remove the nut and insulating bushing at terВminal B, and remove rectifier.

(A) Ractifier

(B) Rear cover

D: ASSEMBLY

S179008A02

To assemble, reverse order of disassembly. 1) Pulling up brush

Before assembling, press the brush down into the brush holder with your finger and secure in that position by passing a [2 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the hole shown in the figure.

(A) Diode lead

(B) Heat sink (Positive side)

2) Checking negative diode Check for continuity between the negative side heat sink and diode lead. The negative diode is in good condition if continuity (1 D. or less) exists only in the direction from the heat sink to the diode lead.

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GENERATOR

Starting/Charging Systems

4) Insulation test

Check continuity between slip ring and rotor core or shaft. If continuity (1 D. or less) exists, the rotor coil is grounded, and so replace rotor assembly.

(A) Diode lead

(B) Heat sink (Negative side)

2. ROTOR

S179008A1002

1) Slip ring surface

Inspect slip rings for contamination or any roughВness of the sliding surface. Repair slip ring surface using a lathe or sand paper.

2) Slip ring outer diameter

Measure slip ring outer diameter. If slip ring is worn replace rotor assembly.

Slip ring outer diameter: Standard

22.7 mm (0.894 in) Limit

22.1 mm (0.870 in)

3) Continuity test

Check resistance between slip rings using circuit

tester.

If the resistance is not within specification, replace

rotor assembly.

Specified resistance: Approx. 2.7-3.2 D.

5) Ball bearing (rear side)

(1) Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly.

(2) The rear bearing can be removed by using common bearing puller.

3. STATOR

S179008A1003

1) Continuity test

Inspect stator coil for continuity between each end of the lead wires. If there is no continuity (1 D. or more) between individual lead wires, the lead wire is broken, and so replace stator assembly.

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GENERATOR

Starting/Charging Systems

2) Insulation test

Inspect stator coil for continuity (1 D. or less) between stator core and each end of the lead wire. If there is continuity, the stator coil is grounded, and so replace stator assembly.

2) Checking brush spring for proper pressure Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of the brush spring. If the pressure is less than 2.648 N (270 g, 9.52 oz), replace the brush spring with a new one. The new spring must have a pressure of 4.609 to 5.786 N (470 to 590 g, 16.58 to 20.81 oz).

4. BRUSH

S179008A1004

1) Measure the length of each brush. If wear exceeds the service limit, replace the brush. Each brush has the service limit mark (A) on it.

Brush length: Standard

18.5 mm (0.728 in) Service limit

5.0 mm (0.197 in)

5. BEARING (FRONT SIDE)

S179008A1005

1) Check front ball bearing. If resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing.

2) Replacing front bearing

(1) Remove front bearing retainer.

(2) Closely install a fit tool on the bearing inner race. Press the bearing down out of front bracket with a hand press or vise. A socket wrench can serve as the tool.

(A) Front bracket

(B) Socket wrench

(3) Set a new bearing and closely install a fit tool on the bearing outer race. Press the bearВing down into place with a hand press or vise. A socket wrench can serve as the tool.

(4) Install front bearing retainer.

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GENERATOR

Starting/Charging Systems

		- Non-Turbo Model
3. Generator	S179008


A: REMOVAL	S179008A18
1) Disconnect battery ground cable.

		- Turbo Model

2) Disconnect connector and terminal from genВerator. - Non-Turbo Model

		4) Remove front side V-belt. <Ref. to ME(SOHC) -42, FRONT SIDE, REMOVAL, V-belt.> or <Ref. to ME(DOHC TURBO) -44, FRONT SIDE, REMOVAL, V-belt.> 5) Remove bolts which install generator onto bracket.
- Turbo Model



3) Remove V-belt cover.

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GENERATOR

Starting/Charging Systems

		4) Insulation test Check continuity between slip ring and rotor core or shaft. If continuity (1 D. or less) exists, the rotor coil is grounded, and so replace rotor assembly.

(A) Diode lead (B) Heat sink (Negative side)
2. ROTOR	S179008A1002

1) Slip ring surface Inspect slip rings for contamination or any roughВness of the sliding surface. Repair slip ring surface using a lathe or sand paper. 2) Slip ring outer diameter Measure slip ring outer diameter. If slip ring is worn replace rotor assembly. *Slip ring outer diameter: Standard* *22.7 mm (0.894 in) Limit* *22.1 mm (0.870 in)* 3) Continuity test Check resistance between slip rings using circuit tester. If the resistance is not within specification, replace rotor assembly. *Specified resistance: Approx. 2.7-3.2 D.*			5) Ball bearing (rear side) (1) Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly. (2) The rear bearing can be removed by using common bearing puller.

			3. STATOR	S179008A1003
			1) Continuity test Inspect stator coil for continuity between each end of the lead wires. If there is no continuity (1 D. or more) between individual lead wires, the lead wire is broken, and so replace stator assembly.



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GENERATOR

Starting/Charging Systems

2) Insulation test Inspect stator coil for continuity (1 D. or less) between stator core and each end of the lead wire. If there is continuity, the stator coil is grounded, and so replace stator assembly.		2) Checking brush spring for proper pressure Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of the brush spring. If the pressure is less than 2.648 N (270 g, 9.52 oz), replace the brush spring with a new one. The new spring must have a pressure of 4.609 to 5.786 N (470 to 590 g, 16.58 to 20.81 oz).


4. BRUSH	S179008A1004
1) Measure the length of each brush. If wear exceeds the service limit, replace the brush. Each brush has the service limit mark (A) on it. *Brush length: Standard* *18.5 mm (0.728 in) Service limit* *5.0 mm (0.197 in)*

		5. BEARING (FRONT SIDE)	S179008A1005
		1) Check front ball bearing. If resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing. 2) Replacing front bearing (1) Remove front bearing retainer. (2) Closely install a fit tool on the bearing inner race. Press the bearing down out of front bracket with a hand press or vise. A socket wrench can serve as the tool.



(A) Front bracket (B) Socket wrench (3) Set a new bearing and closely install a fit tool on the bearing outer race. Press the bearВing down into place with a hand press or vise. A socket wrench can serve as the tool. (4) Install front bearing retainer.

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	GENERATOR

	Starting/Charging Systems



	(A) Bearing (B) Socket wrench (C) Front bracket

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