Starters (except Outback Sport) Subaru Impreza WRX GD/GG рестайлинг

Scheme 1

Scheme 2

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING

The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test. For these performance tests (Scheme 3)

NO-LOAD TEST

With switch ON, adjust the variable resistance to obtain 11 volts, take the ammeter reading, and then measure the starter speed. Compare the values.

LOAD TEST

Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within specifications.

LOCK TEST

With the starter stalled, or not rotating, measure the torque developed and current draw when voltage is adjusted to the specified voltage.

Scheme 3

ARMATURE

1. Check commutator for any sign of burns of rough surfaces or stepped wear. If wear is of a minor nature, correct it by using sand paper.
2. Check the commutator run-out and replace if it exceeds the limit. (Scheme 4) See «STARTER SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport) table under STARTER SPECIFICATIONS.
3. Check the depth of segment mold. (Scheme 5) See «STARTER SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport) table under STARTER SPECIFICATIONS.
4. Check armature for short-circuit by placing it on growler tester. (Scheme 6) Hold a iron sheet against armature core while slowly rotating armature. A short-circuited armature will cause the iron sheet to vibrate and to be attracted to core. If the iron sheet is attracted or vibrates, the armature, which is short-circuited, must be replaced or repaired.
5. Using a circuit tester, touch one probe to the commutator segment and the other to shaft. (Scheme 7) If there is no continuity, it is normal. If there is continuity armature is grounded. Replace armature if it is grounded.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

BRUSH & BRUSH HOLDER

1. Measure the brush length and replace if it exceeds the service limit. See «STARTER SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport) table under STARTER SPECIFICATIONS. (Scheme 8) Replace if abnormal wear or cracks are noticed.
2. Be sure brush moves smoothly inside brush holder.
3. Measure brush spring force with a spring scale. If it is less than the service limit, replace brush spring. See «STARTER SPECIFICATIONS»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport) table under STARTER SPECIFICATIONS.

Scheme 8

OVERRUNNING CLUTCH

Inspect the teeth of pinion for wear and damage. Replace if it is damaged. Rotate the pinion in direction of rotation (counterclockwise). It should rotate smoothly. But in opposite direction, it should be locked.

PINION GAP

1. Measure the pinion gap while the pinion is pulled out. (Scheme 9) If the motor is running with the pinion forced endwise on shaft, disconnect the connector from terminal M of switch assembly, and then connect terminal M to ground terminal (-) of battery with a lead wire. Next, gently push the pinion back with your fingertips, and then measure the pinion gap.
2. If the pinion gap is outside specified range, remove or add number of adjustment washers used on the mounting surface of switch assembly until correct pinion gap is obtained.

Scheme 9

SWITCH ASSEMBLY

Using a circuit tester (set in "ohm" position), check that there is a continuity between terminals S and M, and between terminal S and ground. (Scheme 10) Also check to be sure there is no continuity between terminals M and B.

Scheme 10

SWITCH ASSEMBLY OPERATION

Note. With the pinion forced endwise of shaft, starter motor can sometimes rotate because current flows, through pull-in coil, to motor. This is not a problem.

1. Connect the terminal S of switch assembly to positive terminal of battery with a lead wire, and starter body to ground terminal of battery. The pinion should be forced endwise on shaft.
2. Disconnect the connector from terminal M, and then connect the positive terminal of battery and terminal M using a lead wire and ground terminal to starter body. (Scheme 11) In this test set up, the pinion should return to its original position even when it is pulled out with a screwdriver.

Scheme 11

YOKE

Make sure the pole is set in position.

Removal

1. Disconnect ground cable from battery.
2. Remove air cleaner case for non-turbo model. See «AIR CLEANER CASE»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport).
3. Remove the intercooler for turbo model. See «INTERCOOLER»(/subaru/impreza-wrx/gdgg-2002-2005/remont/starter/#starters-except-outback-sport).
4. Remove air cleaner case stay. (Scheme 12)
5. Disconnect connector and terminal from starter. (Scheme 13)
6. Remove starter from transmission. (Scheme 14)

Scheme 12

Scheme 13

Scheme 14

Installation

Install in the reverse order of removal. (Scheme 14) Tighten bolts to specifications. See TORQUE SPECIFICATIONS.

Removal & Installation

1. Disconnect the ground cable from battery.
2. Disconnect the connector (A) of intake air temperature sensor.
3. Remove the bolts (B) which install air cleaner case to stay. (Scheme 15)
4. Disconnect the hoses and intake duct from air cleaner case.
5. Loosen the clamp which connects air cleaner case to throttle body. (Scheme 16)
6. Remove the air cleaner case.
7. Install in the reverse order removal.

Scheme 15

Scheme 16

Inspection

Inspect for cracks and loose connections.

1. Disconnect the air by-pass hoses from intercooler. (Scheme 17)
2. Separate the air by-pass valve from intercooler. (Scheme 18)
3. Remove the bolts which secure the intercooler to bracket. (Scheme 19)
4. Separate the intercooler air duct from turbo-charger.
5. Separate the intercooler from throttle body. (Scheme 20)

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Install in the reverse order of removal. (Scheme 21)

Scheme 21

Disassembly

1. Loosen the nut which holds the terminal M of switch assembly, and then disconnect the connector. (Scheme 22) NOTE: Be careful because the pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.
2. Remove the bolts which hold the switch assembly, and then remove switch assembly, plunger and plunger spring from starter as a unit.
3. Remove both through-bolts and brush holder screws, and then detach the rear cover and brush holder. (Scheme 23)
4. Remove the armature and yoke from front bracket. (Scheme 24) The ball used as a bearing will come off from the armature end.
5. Remove packing A, planetary gears, packing B and plate. (Scheme 25) NOTE: Note the direction of the lever before removing.
6. Remove the shaft assembly and overrunning clutch as a unit. (Scheme 26)
7. Remove the overrunning clutch from shaft assembly as follows: Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such as a fit socket wrench). (Scheme 27) Remove the ring, stopper and clutch from shaft.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Brush Holder (Turbo M/T Model)

Note. Only the brush of turbo M/T model starter can be disassembled.

Slightly open the metal fitting while holding the insulating plate against the brush holder. Remove the insulating plate. The brush and spring can be easily removed from the brush holder at this time. (Scheme 28)

Scheme 28

Assembly

1. Assemble in the reverse order of disassembly.
2. Apply grease to the following parts before assembly. Front and rear bracket sleeve bearings Armature shaft gear Outer periphery of plunger Mating surfaces of plunger and lever Gear shaft splines Mating surfaces of lever and clutch Ball at armature shaft end Planetary gear

STARTER SPECIFICATIONS

Note. For additional starter specifications (Scheme 29)or (Scheme 30).

STARTER SPECIFICATIONS

Scheme 29

Scheme 30

TORQUE SPECIFICATIONS

For starter specification for 2002-03 models, see STARTING SYSTEM article in SPECIFICATIONS.

For starter specification for 2004 models, see STARTING SYSTEM article in SPECIFICATIONS.

WIRING DIAGRAMS

For wiring diagram for 2002, see STARTING/CHARGING in SYSTEM WIRING DIAGRAM article in ELECTRICAL.

For wiring diagram for 2003, see STARTING/CHARGING in SYSTEM WIRING DIAGRAM article in ELECTRICAL.

For wiring diagram for 2004, see STARTING/CHARGING in SYSTEM WIRING DIAGRAM article in ELECTRICAL.

See also:
• STARTER SPECIFICATIONS
• TORQUE SPECIFICATIONS