SUBARU LEGACY 1996 Service Repair Manual

B6M0477A
CAUTION:
When holding rotor with vise, insert aluminum plates
or wood pieces on the contact surfaces of the vise to
prevent rotor from damage.
B6M0478A
4) Remove rotor from front cover.
5) Remove three screws from front cover and then bear-
ing retainer and ball bearing.
B6M0479A
6) Remove bolt which secure battery terminal bolt, and
remove rear cover. Remove nuts which secure diode plate,
and remove stator and rear cover.
B6M0480A
7) Separate diode plate from stator coil.
(1) Cut the connecting position

Aof stator coil to
diode.
(2) Unsolder connection

Band throughout the lead
wire of stator coil.
B6M0481
(3) Remove stator coil from diode plate.
17
6-1SERVICE PROCEDURE
2. Generator

B6M0482
8) Remove bolts which secure IC regulator, diode and
brush holder.
CAUTION:
Do not apply a shock or load to IC regulator cooling
fins.
G6M0075
C: INSPECTION AND REPAIR
1. ROTOR
1) Slip ring surface
Inspect slip rings for contamination or any roughness of the
sliding surface.
Clean or polish with #500 to #600 emery paper if defective.
B6M0483A
2) Slip ring outside diameter
Measure slip ring outside diameter. If slip ring is worn,
replace rotor.
Slip ring outside diameter:
Standard
27 mm (1.06 in)
Limit
26 mm (1.02 in)
B6M0484A
3) Continuity test
Check continuity between slip rings. If continuity does not
exist, replace rotor.
B6M0485A
4) Insulation test
Check continuity between slip ring and rotor core or shaft.
If continuity exists, replace rotor.
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6-1SERVICE PROCEDURE
2. Generator

B6M0486
5) Ball bearing
Check rear ball bearing. Replace it if it is noisy or if rotor
does not turn smoothly.
G6M0078
2. STATOR
1) Continuity test
Inspect stator coil for continuity between its terminals.
When there is no continuity between individual terminals,
cable is broken.
Replace stator coil.
G6M0079
2) Insulation test
Inspect stator coil for continuity between stator core and
each terminal. If there is continuity, replace stator coil.
B6M0487A
3. BRUSH
Measure brush length. If brush is worn, replace brush
holder assembly.
Brush length (
):
Standard
20.5 mm (0.807 in)
Limit
1.5 mm (0.059 in)
B6M0488A
4. DIODE ASSEMBLY
The diode consists of eight diodes, four each being located
on the positive and negative sides. The diode is necessary
to restrict current flow to one direction.
Check all diodes, for continuity. If any diode is faulty,
replace diode assembly.
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6-1SERVICE PROCEDURE
2. Generator

B6M0489A
1) Diodes on“+”side
Continuity of proper diodes on“+”side
BAT side
(+) ()
Terminal
N, U, V and W
(+)—Continuity must
not exist.
()Continuity
must exist.—
B6M0490A
2) Diodes on“”side
Continuity of proper diodes on“”side
“E”side
(+) ()
Terminal
N, U, V and W
(+)—Continuity must
exist.
()Continuity
must not exist.—
CAUTION:
Never use a high tension insulation tester, such as a
meggar as it will damage diodes with its high tension.
B6M0491A
5. IC REGULATOR
1) Compose a circuit diagram as shown in figure.


1Voltage meter: 0 to 30 V


2Switch 1


3Variable DC power supply: Variable 0 to 20 V, 1 A or
more


4Lamp 2


5Lamp 1


6Switch 3


7Switch 2


8Plus generator: Power supply 5 to 30 V, 1 kHz
20
6-1SERVICE PROCEDURE
2. Generator

2) Check operation as shown in chart below.
No.Switch operation
Value of
voltage meterLamp operation
Remarks
123 12
1 ON OFF OFF 12 V DIM ONCheck initial
excitation.
2 ON ON OFF 12 VON
or
BLINKOFF Check total excitation.
3 ON ON OFF 16 VOFF
or
DIM-BLINKOFFWhen value of voltage
meter is between 12
V and 16 V.
4 OFF ON OFF 12 VON
or
BLINKONCheck connection for
S and B terminals.
5 OFF ON ON 18 V ON ONCheck for over
loading of voltage.
G6M0077
D: ASSEMBLY
Assembly is in the reverse order of disassembly proce-
dures.
CAUTION:
When disassembling generator, replace rear ball
bearing.
When soldering starter coil to diode, do not touch
lead wire with solder for more than 5 seconds.
B6M0492
Before installing rear cover, insert pin from outside
of rear cover so that holds brush. After installing rear
cover, remove pin.
B6M0476A
When installing rear cover, heat portion
Ato 50°C
(122°F) with heater drier.
21
6-1SERVICE PROCEDURE
2. Generator

3. Spark Plug
A: REMOVAL AND INSTALLATION
CAUTION:
All spark plugs installed on an engine, must be of the
same heat range.
Spark plug:
CHAMPION: RC10YC4
(Alternate)
NGK: BKR6E-11
NIPPONDENSO: K20PR-U11
1) Remove spark plug cords by pulling boot, not cord itself.
2) Remove spark plugs.
3) When installing spark plugs on cylinder head, use spark
plug wrench.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
CAUTION:
The above torque should be only applied to new spark
plugs without oil on their threads.
In case their threads are lubricated, the torque should
be reduced by approximately 1/3 of the specified
torque in order to avoid their over-stressing.
4) Connect spark plug cords.
G6M0086
B: INSPECTION
Check electrodes and inner and outer porcelain of plugs,
noting the type of deposits and the degree of electrode
erosion.
G6M0087
1) Normal
Brown to grayish-tan deposits and slight electrode wear
indicate correct spark plug heat range.
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6-1SERVICE PROCEDURE
3. Spark Plug

G6M0088
2) Carbon fouled
Dry fluffy carbon deposits on insulator and electrode are
mostly caused by slow speed driving in city, weak ignition,
too rich fuel mixture, dirty air cleaner, etc.
It is advisable to replace with plugs having hotter heat
range.
G6M0089
3) Oil fouled
Wet black deposits show excessive oil entrance into com-
bustion chamber through worn rings and pistons or exces-
sive clearance between valve guides and stems. If same
condition remains after repair, use a hotter plug.
G6M0090
4) Overheating
White or light gray insulator with black or gray brown spots
and bluish burnt electrodes indicate engine overheating.
Moreover, the appearance results from incorrect ignition
timing, loose spark plugs, wrong selection of fuel, hotter
range plug, etc. It is advisable to replace with plugs having
colder heat range.
G6M0091
C: CLEANING AND REGAPPING
Clean spark plugs in a sand blast type cleaner.
Avoid excessive blasting. Clean and remove carbon or
oxide deposits, but do not wear away porcelain.
If deposits are too stubborn, discard plugs.
After cleaning spark plugs, recondition firing surface of
electrodes with file. Then correct the spark plug gap using
a gap gauge.
Spark plug gap: L
1.0—1.1 mm (0.039—0.043 in)
D: REMOVAL AND INSTALLATION (2500 cc
EXCEPT OUTBACK MODEL)
CAUTION:
All spark plugs installed on an engine, must be of the
same heat range.
Spark plug:
NGK: PFR5B-11
23
6-1SERVICE PROCEDURE
3. Spark Plug

G6M0095
1. #1 SPARK PLUG
1) Disconnect battery ground cable.
B6M0552A
2) Remove #1 spark plug cord by pulling boot, not cord
itself.
B6M0553
3) Remove spark plug with the spark plug socket.
4) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
G6M0095
2. #2 SPARK PLUG
1) Disconnect battery ground cable.
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6-1SERVICE PROCEDURE
3. Spark Plug

B6M0554
2) Remove battery.
B6M0555A
3) Remove #2 spark plug cord by pulling boot, not cord
itself.
B6M0556
4) Remove spark plug with the spark plug socket.
5) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
G6M0095
3. #3 SPARK PLUG
1) Disconnect battery ground cable.
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6-1SERVICE PROCEDURE
3. Spark Plug

B6M0557A
2) Disconnect mass air flow sensor connector.
3) Remove four clips securing air cleaner upper cover.
B6M0558
4) Loosen the clamp screw and separate air cleaner upper
cover from air intake duct.
5) Remove air cleaner element.
B6M0559A
6) Remove #3 spark plug cord by pulling boot, not cord
itself.
B6M0560
7) Remove spark plug with the spark plug socket.
8) Installation is in the reverse order of removal.
Tightening torque (Spark plug):
20.6±2.9 N⋅m (2.10±0.30 kg-m, 15.19±2.14 ft-lb)
26
6-1SERVICE PROCEDURE
3. Spark Plug