Starting System & Charging System (H4SO): Other Subaru Impreza GH

NON-TURBO MODEL

NON-TURBO MODEL SPECIFICATION CHART

TURBO MODEL

TURBO MODEL SPECIFICATION CHART

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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 burns 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 the battery.

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1. Disconnect the ground cable from the battery.
2. Remove the air intake chamber. (Non-turbo model) Refer to «REMOVAL»(ref-325315-S02698974742009071800000) , Air Intake Chamber.
3. Remove the intercooler. (Turbo model) Refer to «REMOVAL»(ref-325300-S41039960822009071800000) , Intercooler.
4. Remove the air intake chamber stay. (Non-turbo model) MT model AT model
5. Disconnect the connector (B) and terminal (A) from starter.
6. Remove the starter from transmission.

Note. For the MT model, a bolt is used in place (A).

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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 it is damaged. If it rotates smoothly when rotated in the correct direction (counterclockwise) and does not return to the other direction, it is normal.

Scheme 61

1. Brush length Measure the length of the brush. If it exceeds service limits, replace it. Replace if there is abnormal wear or cracks. Brush length: Standard 12.3 mm (0.484 in) Service limit 7.0 mm (0.276 in)
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 lbf) (When new)

Service limit

2.5 N (0.25 kgf, 0.56 lbf)

DIODE

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

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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 assembly 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 assembly. Specified resistance: Approximately 1.8 - 2.2 ohms
4. Insulation test Check the continuity between slip ring and rotor core or shaft. If the resistance is 1 ohms or less, replace the rotor assembly because the rotor coil is grounded.
5. Ball bearings (rear side) Check the rear ball bearing. If there is any noise, or the rotor does not rotate smoothly, replace the bearings.

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1. Continuity test Inspect continuity between the stator coil lead wire terminals. If the resistance is 1 Mohms or more, the lead wire is damaged. Replace the stator assembly.
2. Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If the resistance is 1 ohms or less, the stator coil is grounded. Replace the stator assembly.

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)
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 (0.08 in). Then measure the pressure of brush spring. If the pressure is 2.648 N (270 g, 9.52 oz) or less, replace the brush spring with a new part. 4.609 - 5.786 N (470 - 590 g, 16.58 - 20.810 oz) pressure is required on the new spring.

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BEARING (FRONT SIDE)

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

Scheme 70

1. Disconnect the positive (+) terminal after disconnecting the negative (-) terminal of battery.
2. Remove the harness clip of the negative terminal 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 71

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) Determine whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [20°C(68°F)J
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 (Scheme 71)

MEASUREMENT

JUDGEMENT 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 INDICATOR 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, the 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.