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

INSTALLATION

Install in the reverse order of removal.

Tightening torque

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

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1. Disconnect M terminal (A) from magnet switch assembly.
2. Remove the magnet switch assembly from the starter housing assembly.
3. Remove through bolts (A) on both sides and the brush holder screws (B), and remove the starter cover assembly.
4. Remove the yoke assembly and brush holder assembly as a unit.
5. Remove the two brushes wired to the yoke assembly, and separate the yoke assembly and the brush holder assembly. NOTE: As shown in the figure, use a flat tip screwdriver, etc. to hold the brush spring and remove the brush.
6. Remove the armature from the internal gear assembly.
7. Remove the starter housing assembly (A) then remove the shift lever (B).
8. Use the following procedures to remove the overrunning clutch from the shaft. Use an appropriate tool (such as a fit socket wrench), and remove the stopper from snap ring by lightly tapping the stopper with a plastic hammer. Remove snap ring (A) from the shaft, and remove stopper (B). Remove the overrunning clutch from the shaft.
9. Use the following procedures to remove the shaft. Remove the starter plate, and remove the pinion gear. Remove the snap ring from the shaft. Remove the shaft from the internal gear assembly.

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1. Use the following procedures to install the shaft. Apply grease to the sliding surfaces of the internal gear assembly shaft. Grease: DENSO HL50 Assemble the shaft to the internal gear assembly. Install the snap ring to shaft. NOTE: Use new snap rings. Apply grease to the pinion gear attachment area. Grease: DENSO HL50 Attach the pinion gear to the pin. Apply grease to the pinion gear, internal gear assembly, and on top of the shaft pin. NOTE: Apply grease so that it contacts each gear. Be careful not to allow dirt to get in. Grease: DENSO HL50 Install the starter plate.
2. Assemble the overrunning clutch and shift lever (B) to the starter housing (A) as a unit. NOTE: Apply grease to the contact portion of the shift lever. Grease: DENSO HL50
3. Assemble the overrunning clutch as follows: Apply grease to the spline portion of the shaft. Grease: DENSO HL50 Install the overrunning clutch to shaft. Pass stopper (B) through the shaft, and attach snap ring (A). NOTE: Use new snap rings. Using a press, pressure fit stopper (B) into snap ring (A).
4. Install the armature to the internal gear assembly.
5. Attach the two brushes wired to the yoke assembly to the brush holder assembly. NOTE: As shown in the figure, use a flat tip screwdriver, etc. to hold the brush spring and insert the brush while being careful not to damage the brush.
6. Install the yoke assembly and brush holder assembly as a single unit to the armature. NOTE: Spread the brush with your fingers, being careful not to damage the brush.
7. Install starter cover assembly to the brush holder assembly with screws (B). Tightening torque: 1.4 N.m (0.1 kgf-m, 1.0 ft-lb)
8. Tighten the through bolts (A) on both sides. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)
9. Attach the magnet switch assembly to the starter housing assembly. Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
10. Connect M terminal (A) to magnet switch assembly. 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. Check for runout on the commutator. If excessive, replace the armature. Commutator runout: Standard 0.05 mm (0.0020 in) Limit 0.10 mm (0.0039 in)
3. Check the depth of the segment mold. If it is not within the standard, replace the armature. Depth of segment mold: Standard 0.5 mm (0.020 in)
4. Place the armature on the growler tester to check for short circuits. While slowly turning the armature, support the steel sheet for the armature core. If the circuit of the armature is shorted, the steel sheet will vibrate, causing it to move towards the core. When the steel sheet has moved or vibrated, replace the armature.
5. 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 continuity, 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)

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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 nut. 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.