Generators & Regulators (except Outback Sport) Subaru Impreza WRX GD/GG рестайлинг

APPLICATION

GENERATOR APPLICATION

DESCRIPTION & OPERATION

The generator has a built-in regulator with diagnostic functions and voltage regulating functions, such as the following

1. Voltage regulation: The On-Off operation of transistor TR 1 connects and disconnects the field current circuit which provides a constant output voltage level. (Scheme 1)
2. Diagnosis warning is when any of the following problems occur the charge lamp illuminates: No voltage generation: Brush wear exceeds specified wear limits, field coil circuit is broken, etc. Excessive output: Output voltage is greater than 16 volts (approximately.) Terminal B disconnection: Harness is disconnected from alternator terminal B. Terminal S disconnection: Harness is disconnected from alternator terminal S. In this case, voltage is slightly greater than specified regulated voltage; however, voltage regulation is still controlled and the battery is prevented from overcharging.

Scheme 1

Scheme 2

BELT TENSION

Measure deflection with 22 Lbs. (98 N) of force applied between generator and crankshaft pulley belt run. (Scheme 3) If deflection is not within specification, adjust belt. See BELT DEFLECTION table.

BELT DEFLECTION

Scheme 3

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

BRUSH

1. Measure the length of each brush. (Scheme 4) If wear exceeds the service limit, replace the brush. Each has the service limit mark (A) on it. See «BRUSH SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport) table under GENERATOR SPECIFICATIONS.
2. Checking brush for proper pressure using a spring pressure indicator, push the brush into the brush holder until its tip protrudes.08" (2 mm). (Scheme 5) Then measure the pressure of brush spring. See «BRUSH SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport) table under GENERATOR SPECIFICATIONS.

Scheme 4

Scheme 5

DIODE

1. Check for continuity between the diode lead and positive side heat sink. (Scheme 6) The positive diode is in good condition if resistance is 1 ohms or less only in the direction from the diode lead to heat sink.
2. Check for continuity between the negative side heat sink and diode lead. (Scheme 7) The negative diode is in good condition if resistance is 1 ohms or less only in the direction from the heat sink to diode lead.

Scheme 6

Scheme 7

ROTOR

1. Inspect the slip rings for contamination or any roughness of the sliding surface. Repair the slip ring surface using a lathe or sand paper.
2. Measure the slip ring outer diameter. See «ROTOR ASSEMBLY SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport) table under GENERATOR SPECIFICATIONS. If the slip ring is worn replace rotor assembly.
3. Check the resistance between slip rings using circuit tester. (Scheme 8)
4. Check the continuity between slip ring and rotor core or shaft. (Scheme 9) If resistance is 1 ohm or less, the rotor coil is grounded, and so replace the rotor assembly.
5. Check the rear ball bearing. Replace if it is noisy or if the rotor does not turn smoothly.

Scheme 8

Scheme 9

STATOR

1. Inspect the stator coil for continuity between each end of the lead wires. (Scheme 10) If resistance is 1 ohms or more, the lead wire is broken, and so replace the stator assembly.
2. Inspect the stator coil for continuity between stator core and each end of lead wire. (Scheme 11) If resistance is 1 ohm or less, the stator coil is grounded, and so replace the stator assembly.

Scheme 10

Scheme 11

Removal

1. Disconnect ground cable from battery.
2. Disconnect connector and terminal from generator. (Scheme 12)or (Scheme 13).
3. Remove V-belt. See «V-BELT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport).
4. Remove bolt (A), and loosen bolt (B). Then, remove generator from bracket. (Scheme 14)

Scheme 12

Scheme 13

Scheme 14

Installation

Install in the reverse order of removal. (Scheme 14)

Note. Perform the following procedures with the engine installed to body.

1. Remove the V-belt cover. (Scheme 15)
2. Loosen the lock bolt (A). (Scheme 16)
3. Loosen the slider bolt (B).
4. Remove the front side belt (C).

Scheme 15

Scheme 16

Note. Wipe off any oil or water on the belt and pulley.

1. Install the belt (C), and tighten the slider bolt so as to obtain the specified belt tension. See «BELT TENSION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport__belt-tension) under ADJUSTMENTS. (Scheme 16)
2. Tighten the lock bolt (A).
3. Tighten the slider bolt (B). See «TORQUE SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/charging-system/#generators-regulators-except-outback-sport__torque-specifications).

OVERHAUL

Disassembly

1. Remove the 4 through-bolts (Scheme 17)
2. Heat the portion (A) of rear cover to 122°F (50°C) with heater drier. (Scheme 18)
3. Insert the tip of a flat-head screwdriver into the gap between the stator core and front cover. Pry them apart to disassemble. (Scheme 19) CAUTION: To prevent rotor damage when holding rotor with vise, insert aluminum plates or wood pieces on vise's contact surfaces.
4. Hold rotor with a vise and remove pulley nut. (Scheme 20)and (Scheme 21). CAUTION: Rectifier cannot withstand heat well. Finish below steps rapidly (less than 3 seconds).
5. Remove the ball bearing as follows: Remove bolt, then remove bearing retainer. (Scheme 22)Firmly install to bearing inner race an appropriate tool, such as a fit socket wrench. (Scheme 23) Push the ball bearing off the front cover using a press.
6. Remove bearing from rotor using a bearing puller. (Scheme 24) CAUTION: The rectifier cannot withstand heat well. Do not allow the 180-270 watt soldering bit to contact the terminals for more than 5 seconds at a time.
7. Unsolder connection between rectifier and stator coil to remove stator coil. (Scheme 25)
8. Remove IC regulator as follows: Remove screws that secure the IC regulator to the rear cover. (Scheme 26) Unsolder connection between IC regulator and rectifier to remove IC regulator. (Scheme 27)
9. Remove brush as follows: Remove cover A. (Scheme 28) Remove cover B. (Scheme 29) Separate brush from connection to remove. (Scheme 30)
10. Remove rectifier as follows: Remove bolts that secure rectifier. (Scheme 31) Remove terminal B's cover. (Scheme 32) Remove nut from terminal B. (Scheme 33) Remove rectifier.

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Assembly

Assemble generator in reverse order of disassembly procedure.

1. Before assembling, press the brush down into the brush holder. Fix it in that position by passing a wire (A).08" (1 mm) diameter length 1.6-2" (40-50 mm) wire through the hole. (Scheme 34)
2. Install ball bearing using following steps: Set the ball bearing on the front cover. Securely install to the bearing outer race an appropriate tool, such as a fit socket wrench. Press the ball bearing into the specified position using a press. Install the bearing retainer.
3. Install the bearing (rear side) into the rotor shaft with a press. CAUTION: Grease should not be applied to rear bearing. Completely remove the oil if found on bearing box.
4. Heat the bearing box in the rear cover to 122-140°F (50-60°C). Then, press the rear bearing into the rear cover.
5. After reassembly, turn the pulley by hand to check that the rotor turns smoothly.

Scheme 34

GENERATOR SPECIFICATIONS

BRUSH SPECIFICATIONS

ROTOR ASSEMBLY SPECIFICATIONS

Scheme 35

TORQUE SPECIFICATIONS

TORQUE SPECIFICATION

WIRING DIAGRAMS

For wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAM article in ELECTRICAL.

See also:
• BELT DEFLECTION
• BELT TENSION
• TORQUE SPECIFICATIONS
• BRUSH