Starting/charging (H4SO): Other Subaru Forester SG рестайлинг

CAUTION

1. Wear work clothing, including a cap, protective goggles and protective shoes during operation.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Be careful not to burn your hands, because each part on the vehicle is hot after running.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Disconnect the ground cable from battery. (Scheme 55): Disconnecting Battery Ground Cable
2. Remove the collector cover. (Turbo model)
3. Remove the air intake chamber. (Non-turbo model) REMOVAL Air Intake Chamber. >
4. Remove the intercooler. (Turbo model) REMOVAL Intercooler. >
5. Remove the air intake chamber stay LH. (Non-turbo model) MT model (Scheme 56): Identifying Air Cleaner Case Stay - MT Model AT model (Scheme 57): Identifying Air Cleaner Case Stay - AT Model
6. Disconnect the connector and terminal from starter. (Scheme 58): Identifying Connector And Terminal From Starter
7. Remove the starter from transmission.

Note. For MT model, the bolt is used in place of nut (A) shown in the figure.

Identifying Starter Nut And Bolt - AT Model. Scheme 59

YOKE

Make sure that the pole is set at the predetermined position.

OVERRUNNING CLUTCH

Check that there is no wear or damage to the piston teeth. Replace if damaged. If it rotates smoothly when rotated in the correct rotation direction (counterclockwise) and does not return to the other direction, it is normal.

Scheme 60

1. Brush length Measure the length of the brush. If it exceeds service limits, replace it. Replace if there is wear or fissures. Brush length: Standard: 12.3 mm (0.484 in) Service limit: 7.0 mm (0.276 in) (Scheme 60): Identifying Service Limit Line And Brush
2. Brush movement: Check that the brush moves smoothly in the brush holder.
3. Brush spring force

Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit.

Brush spring force

Standard: 15.9 - 19.5 N (1.62 - 1.99 kgf, 3.57 - 4.38 lb) (When new)

Service limit: 2.5 N (0.25 kgf, 0.56 lb)

DIODE

Scheme 61

1. Check the positive diode Check the continuity between the diode lead and positive side heat sink. If resistance is 1ohms or less only in the direction from the diode lead to the heat sink, the positive diode is normal. (Scheme 61): Checking Continuity Between Diode Lead And Positive Side Heat Sink
2. Check negative diode

Check the continuity between the diode lead and negative side heat sink. If resistance is 1ohms or less only in the direction from the heat sink to the diode lead, the negative diode is normal.

Checking Continuity Between Diode Lead And Negative Side Heat Sink. Scheme 62

Scheme 63

Scheme 64

1. Slip ring surface Check that there is no dirt on the slip ring or roughness in 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. Replace the rotor assembly if the slip ring is worn. Slip ring outer diameter: Standard: 22.7 mm (0.894 in) Tolerance limit value: 22.1 mm (0.870 in)
3. Continuity test Using a circuit tester, check the resistance between slip rings. Replace the rotor assembly if the resistance is not within the specified value. Specified resistance: Approximately 1.8 - 2.2 ohms (Scheme 63): Checking Resistance Between Slip Rings
4. Insulation test Check the continuity between the slip ring and the rotor core or shaft. If the resistance is 1ohms or less, replace the rotor assembly because the rotor coil is grounded. (Scheme 64): Checking Continuity Between Slip Ring And Rotor Core Or Shaft
5. Ball bearings (rear side) Check the rear ball bearings. If there is any noise, or the rotor does not rotate smoothly, replace.

Scheme 65

Scheme 66

1. Continuity test Inspect the continuity between the stator coil lead wire terminals. If the resistance is 1 Mohms or more, replace the stator assembly because the lead wire is damaged. (Scheme 65): Checking Continuity Between Stator Coil Lead Wire Terminals
2. Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If the resistance is 1ohms or less, replace the stator assembly because the stator coil is grounded. (Scheme 66): Checking Continuity Between Stator Coil Stator Core And Lead Wire Terminals

Scheme 67

Scheme 68

1. Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush. Brush length: Standard: 18.5 mm (0.728 in) Service limit: 5.0 mm (0.197 in) (Scheme 67): Identifying Brush Length Dimension
2. Check that there is appropriate pressure on the brush spring. Use a spring pressure indicator to push the brush into the brush holder until the leading end protrudes 2 mm (0.08 in). Then, measure the brush spring pressure. If the pressure is 2.2 N (224 g, 7.91 oz) or less, replace the brush spring with a new part. 4.8 - 6.0 N (489 - 612 g, 17.26 - 21.60 oz) pressure is required for the new spring. (Scheme 68): Checking Brush Spring For Proper Pressure

BEARINGS (FRONT SIDE)

Check the front ball bearings. Replace the ball bearings if there is resistance in the rotation, or if there is noise.

Scheme 69

1. Disconnect the positive (+) terminal after disconnecting the negative (-) terminal of battery.
2. Remove the flange nut from battery rod and remove battery holder. (Scheme 69): Locating Battery Holder Flange Nut
3. Remove the battery.

EXTERNAL PARTS

Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth.

Apply a thin coat of grease on the terminal posts to prevent corrosion.

ELECTROLYTE LEVEL

Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX LEVEL.

Scheme 70

1. Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following equation: S 20 = St + 0.0007 x (t - 20) S 20: Specific gravity corrected at electrolytic solution temperature of 20°C (68°F) St: Measured specific gravity t: Measured temperature (°C) Determine whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20°C (68°F)] (Scheme 70): Specific Gravity Graph
2. Measuring the specific gravity of the electrolytic solution in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.

MEASUREMENT

JUDGMENT OF BATTERY IN CHARGED CONDITION

1. Specific gravity of electrolyte should be held within the specific range from 1.250 to 1.290 for more than one hour.
2. Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for more than one hour.

CHECK CONDITION OF CHARGE WITH HYDROMETER

CONDITION OF CHARGE WITH HYDROMETER

NORMAL CHARGING

Charge the battery at the current value specified by manufacturer or at approximately 1/10 of battery's ampere-hour rating.

QUICK CHARGING

Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger.

Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40°C (104°F).

Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule.