Starting System & Charging System (H4SO): Removal & Installation Subaru Impreza GH

INSTALLATION

Install in the reverse order of removal.

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

Tightening torque

50 N.m (5.1 kgf-m, 36.9 ft-lb)

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1. Loosen the nuts fastening the magnet switch assembly M terminal, then disconnect the harness from the terminal.
2. Remove the screws fastening the magnet switch assembly, then remove the magnet switch assembly from the starter housing assembly.
3. Remove screws (A) of the brush holder assembly, and through bolts (B) on both sides, and remove the starter cover assembly.
4. Remove the brush holder assembly from the armature assembly. NOTE: Hold the brush with your fingers so that the brush spring does not come flying out.
5. Remove the armature assembly and yoke assembly from the starter housing assembly together as a single unit.
6. Separate the armature assembly and yoke assembly.
7. Remove the pinion gear from the internal gear assembly.
8. Remove the rubber seal (A), plate (B), and rubber seal (C).
9. Lightly tap the starter housing assembly with a plastic hammer as shown in the figure, and remove the overrunning clutch, internal gear assembly, shaft and shift lever together as one piece.
10. Use the following procedures to remove the overrunning clutch from the shaft. Use an appropriate tool (such as correctly sized socket wrenches) to lightly tap on the stopper to remove it from the snap ring. Remove snap ring (A) from the shaft, and remove stopper (B). Remove the overrunning clutch from the shaft.
11. Separate the internal gear assembly and shaft.

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1. Apply grease to the shaft sliding surfaces of the internal gear assembly. Grease: Marutemp #6129 or equivalent
2. Assemble the shaft to the internal gear assembly.
3. Use the procedures below to assemble the overrunning clutch. Apply grease to the splines of the shaft. Grease: Marutemp #6129 or equivalent Attach the overrunning clutch to the shaft. Pass stopper (B) through the shaft assembly, and attach snap ring (A). NOTE: Use new stoppers and snap rings. Using a press, pressure fit stopper (B) into snap ring (A).
4. Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly. NOTE: Apply grease to the moving parts of the shift lever. Grease: Marutemp #6129 or equivalent
5. Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly. NOTE: Apply grease evenly to the contact surfaces of each gear. Be careful that no debris becomes attached. Grease: Molykote® AG650 or equivalent
6. Attach rubber seal (A), plate (B), and rubber seal (C).
7. Assemble the armature assembly to the yoke assembly.
8. Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit. NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.
9. Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly. NOTE: Be careful not to damage the brushes.
10. Attach the starter cover assembly, and affix to the brush holder assembly with screws (A). Tightening torque: 1.4 N.m (0.1 kgf-m, 1.0 it-lb)
11. Tighten through bolts (B) on both sides. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)
12. Attach the magnet switch assembly to the starter housing assembly, and tighten the screws. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
13. Attach the harness to the M terminal of the magnet switch assembly, and tighten the nuts.

Tightening torque

10 N.m (1.0 kgf-m, 7.4 ft-lb)

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1. Check the commutator for signs of seizure or stepped wear caused by roughness of the surface. If there is light wear, use sandpaper to repair.
2. Run-out test Check for run-out on the commutator. If excessive, replace it. Commutator run-out: Standard 0.05 mm (0.0020 in) Service limit 0.10 mm (0.0039 in) or less
3. Depth of segment mold Check the depth of the segment mold. Depth of segment mold: 0.5 mm (0.020 in)
4. Armature short-circuit test Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel seat for the armature core. If the circuit of the armature is shorted, the steel seat will vibrate, causing it to move towards the core. When the steel seat has moved or vibrated, replace or repair the armature with the shorted circuit.
5. Armature ground test Use a circuit tester to touch the probe of one side to the commutator segment, and the other probe to the shaft. If there is no continuity, it is normal. If there is continuity, the armature is grounded. If grounded, replace the armature.

Install in the reverse order of removal.

Tightening torque

25 N.m (2.5 kgf-m, 18.4 ft-lb)

Tightening torque

13 N.m (1.3 kgf-m, 9.6 ft-lb)

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)

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1. Remove the four through-bolts.
2. Use a drier to heat the rear cover (A) portion to 50°C (122°F).
3. Insert the end of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.
4. Using a vise, support the rotor and remove the pulley bolt. 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. Disconnect the connection between the rectifier and stator coil, then remove the stator coil. CAUTION: The rectifier is easily damaged by heat. Do not allow a 180 - 270 W soldering iron to contact the terminals for 5 seconds or more at a time.
8. Use the following procedures to remove the IC regulator. Remove the screws which secure the IC regulator to the rear cover. Disconnect the connection between the IC regulator and rectifier, 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 bolts which secure the rectifier. Remove the cover on B terminal. Remove the nuts of B terminal, then remove the rectifier.

Install in the reverse order of removal.

Tightening torque

3.5 N.m (0.4 kgf-m, 2.6 ft-lb)

Note. Clean the battery cable terminals and apply grease to retard the formation of corrosion. Connect the battery positive (+) terminal, and then connect the negative (-) terminal. After the battery is installed, initial diagnosis of the electronic throttle control is performed. Therefore, start the engine 10 seconds or more after have turning the ignition switch to ON.