Starting System & Charging System (H4DO): Other Subaru Forester SH рестайлинг

NON-TURBO MODEL

GENERAL SPECIFICATION CHART

TURBO MODEL

GENERAL SPECIFICATION CHART

Scheme 39

Tightening torque: N.m (kgf-m, ft-lb)

T1: 1.4 (0.1, 1.0)

T2: 6 (0.6, 4.4)

T3: 7.5 (0.8, 5.5)

T4: 10 (1.0, 7.4)

Scheme 40

Tightening torque: N.m (kgf-m, ft-lb)

T1: 2 (0.2, 1.5)

T2: 3.9 (0.4, 2.9)

T3: 4.4 (0.4, 3.2)

T4: 8.9 (0.9, 6.6)

T5: 108 (11.0, 79.8)

Scheme 41

Scheme 42

1. Non-turbo model Tightening torque: N.m (kgf-m, ft-lb) T1: 8.5 (0.9, 6.3) T2: 16 (1.6, 11.8) T3: 25 (2.5, 18.4) T4: 36 (3.7, 26.6) * Tighten the generator and V-belt cover brackets in the numerical order. * Tighten the power steering pump bracket in the numerical order.
2. Turbo model Tightening torque: N.m (kgf-m, ft-lb) T1: 8.5 (0.9, 6.3) T2: 16 (1.6, 11.8) T3: 22 (2.2, 16.2) T4: 25 (2.5, 18.4)

CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
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. Vehicle components are extremely hot after driving. Be wary of receiving bums from heated parts.
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.

GENERAL TOOL

SPECIAL TOOLS DESCRIPTION CHART

Scheme 43

Scheme 44

Scheme 45

1. Disconnect the ground cable from battery.
2. Remove the air intake boot, (non-turbo model) < Ref. to «REMOVAL»(ref-465389-S17109226172012042000000) , Air Intake Boot >
3. Remove the intercooler. (turbo model) < Ref. to «REMOVAL»(ref-465391-S41396632522012042000000) , Intercooler. >
4. Disconnect the connector (B) and terminal (A) from starter.
5. Remove the starter from transmission. NOTE: For the AT model, a nut is used at (A).

YOKE

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

OVERRUNNING CLUTCH

Inspect the pinion, and if there is any wear or damage, replace the overrunning clutch. Also, check that the pinion rotates counterclockwise smoothly and does not rotate clockwise. If there is any fault, replace the overrunning clutch.

Scheme 46

1. Visually check the brush. If there is any abnormal wear or cracks, replace the brush.
2. Measure the length of the brush. If it exceeds service limits, replace the brush. Brush length: Standard 12.3 mm (0.484 in) Limit 7.0 mm (0.276 in)
3. Check that the brush moves smoothly in the brush holder.
4. 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 lbf) (When new) Limit 2.5 N (0.25 kgf, 0.56 lbf)

Scheme 47

Scheme 48

1. Install the generator to the bracket. Tightening torque: T1: 22 N.m (2.2 kgf-m, 16.2 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
2. Install the front side belt. < Ref. to «FRONT SIDE BELT»(ref-465392-S22191342752012042000000) , INSTALLATION, V-belt. >
3. Connect the connector (A) and terminal (B) to the generator. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
4. Install the collector cover bracket. Tightening torque: T1: 8.5 N.m (0.9 kgf-m, 6.3 ft-lb) T2: 25 N.m (2.5 kgf-m, 18.4 ft-lb)
5. Connect the battery ground terminal.
6. Install the collector cover.

Scheme 49

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Scheme 64

1. Remove the four through bolts.
2. Use a drier to heat the rear cover (A) portion to 50 - 60°C (122 - 140°F).
3. Insert the flat tip screwdriver into the gap between stator core and front cover to disassemble.
4. Using a vise, support the rotor and remove the pulley nut, then remove the rotor from the front cover. CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.
5. Use the following procedures to remove the ball bearings. Remove the bolt, and then detach the bearing retainer. Firmly attach an appropriate tool (such as a correct size socket wrench) to the bearing inner race. Use the press to push the ball bearings out from the front cover.
6. Using the bearing puller, remove the bearings from the rotor.
7. Remove six bolts which connect the rectifier and stator coil, then remove the stator coil.
8. Remove four screws which secure the IC regulator to the rear cover, then remove the IC regulator.
9. Use the following procedures to remove the brush. Remove the cover A. Remove the cover B. Disconnect the connection and remove the brush.
10. Remove the rectifier as follows. Remove the cover on terminal B. Remove the nut on terminal B. Remove the bolts which secure the rectifier, and remove the rectifier.

DIODE

Scheme 65

1. Check for continuity between the diode lead and terminal E or B. If continuity is not as shown in the table, replace the rectifier. At analog type tester TERMINAL CONTINUITY REFERENCE CHART Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 Yes B No P1, P2, P3, P4, P5, P6 E No B Yes At digital type tester TERMINAL CONTINUITY REFERENCE CHART Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 No B Yes P1, P2, P3, P4, P5, P6 E Yes B No

Scheme 66

Scheme 67

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. Replace the rotor if the slip ring is worn. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Limit 22.1 mm (0.870 in)
3. Continuity test Using a circuit tester, check the resistance between slip rings. If the resistance is not within the standard, replace the rotor. Standard: Approx. 2.0 - 2.4 ohms
4. Insulation test Check the continuity between slip ring and rotor core or shaft. If there is continuity, replace the rotor because the rotor coil is grounded.
5. Bearing Check the bearings. If there is any noise, or the rotor does not rotate smoothly, replace the bearings.

Scheme 68

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Scheme 70

1. Continuity test Inspect the continuity between the stator coil terminals. If continuity is not as shown in the table, replace the stator coil.
2. Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If there is continuity, replace the stator coil because the stator coil is grounded.

Scheme 71

Scheme 72

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 (1) 18.5 mm (0.728 in) Limit (2) 5.0 mm (0.197 in)
2. Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.0787 in). Then measure the pressure of brush spring. If the pressure is 1.7 N (173 gf, 6.11 ozf) or less, replace the brush spring. 4.1 - 5.3 N (418 - 540 gf, 14.75 - 19.06 ozf) pressure is required on the new spring.

BALL BEARING

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

Scheme 73

1. Disconnect the positive (+) terminal after disconnecting the negative (-) terminal of battery.
2. Remove the battery cable holder from the battery rod.
3. Remove the flange nut from battery rod and remove battery holder.
4. 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 74

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 calculation: S 20 = St + 0.0007 x (t - 20) S 20 : Specific gravity corrected at electrolyte temperature of 20°C St: Measured specific gravity t: Measured temperature (°C) Judge whether or not the battery requires charging according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20°C (68°F)]
2. Measuring the specific gravity of the electrolyte 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 of 1.250 - 1.290 for one hour or more.
2. Voltage per battery cell should be held at a specific value in a range of 2.5 - 2, 8 V for one hour or more.

CHECK CONDITION OF CHARGE WITH HYDROMETER

HYDROMETER REFERENCE CHART

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, quick charging must be carried out within a current range that will not raise the electrolyte temperature to 40°C (104°F) or more.

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.