Starter - Reduction Gear Subaru Legacy BC/BJ/BF

DESCRIPTION

Legacy & Loyale use Nippondenso and XT and XT6 use Mitsubishi 4-brush, solenoid-actuated, reduction gear starters, equipped with overrunning clutches. The 4-brush holder assembly retains brushes and springs in the rear cover of starter housing.

CRANKING TEST

1. Ensure vehicle has fully charged battery. Connect voltmeter to battery terminals and ammeter to battery cables as per meters' instructions. Disable distributor from firing spark plugs.
2. Crank engine for less than 30 seconds. When cranking engine, note and record voltmeter reading (voltage drop) and ammeter reading (current draw).
3. Normal average starter cranking voltage should be greater than 8 volts with a current draw of about 200 amps or less.

Legacy A/T

1. Turn ignition switch to START position and check for near battery voltage at starter solenoid terminal No. 50 (Red/Yellow wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at inhibitor switch Red/Yellow wire terminal.
2. Inhibitor switch is located on gear select lever, under console. Ensure lever is in Park or Neutral. If voltage exists at inhibitor switch Red/Yellow wire terminal, check for open or short in wiring to starter. If low or no voltage exists at inhibitor switch, check inhibitor switch Blue/Red wire for input voltage when ignition switch is turned to START position.
3. If voltage exists at inhibitor switch Blue/Red wire terminal, replace inhibitor switch. If voltage does not exist at inhibitor switch Blue/Red wire terminal, check for near battery voltage at ignition switch "S" terminal (Blue/Red wire) when ignition switch is turned to START position. If voltage does not exist at ignition switch Blue/Red wire, check for battery voltage to ignition switch. If battery voltage exists at battery terminal (BAT) of switch, replace ignition switch.

Scheme 1

1. Turn ignition switch to START position and check for near battery voltage at starter solenoid terminal No. 50 (Red/Yellow wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at terminal No. 3 (Red/Yellow wire) of interlock relay with clutch pedal fully pressed to floor. (Scheme 1)
2. When clutch pedal is pressed to floor, clutch switch grounds interlock relay terminal No. 1 (Green/Yellow wire), which energizes interlock relay. Interlock relay has a Blue 4-terminal connector and is located on brake pedal bracket, next to brakelight switch. Clutch switch is located at top of clutch pedal arm.
3. If voltage exists at relay terminal No. 3 (Red/Yellow wire), repair wiring between relay and starter. If voltage does not exist, check for near battery voltage at interlock relay terminals No. 2 and 4 (Blue/Red wires) when ignition switch is turned to START position. (Scheme 1) If voltage exists at relay terminals No. 2 and 4, go to step 5).
4. If voltage does not exist at relay terminals No. 2 and 4, check for voltage to ignition switch BAT terminal and from ignition switch START terminal. Repair wiring or replace switch as required. If voltage exists at START terminal, repair Blue/Red wiring between ignition switch and relay terminals No. 2 and 4.
5. If voltage exists at relay terminals No. 2 and 4, ground interlock relay terminal No. 1 (Green/Yellow wire) using jumper wire. Check for near battery voltage at relay terminal No. 3 (Red/Yellow wire). If voltage exists, replace clutch switch. If voltage does not exist, replace relay.

Loyale A/T

1. Ensure gear select lever is in Park or Neutral. Turn ignition switch to START position and check for near battery voltage at starter solenoid terminal No. 50 (Black/White wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at inhibitor switch Black/White wire terminal.
2. Inhibitor switch for models equipped with 3AT transmission is located on gear select lever, under console. Inhibitor switch for models equipped with 4AT transmission is located on transmission lever. If near battery voltage exists at inhibitor switch Black/White wire terminal, repair wiring between inhibitor switch and starter.
3. If voltage does not exist at inhibitor switch Black/White wire terminal, check for voltage at Black/Yellow wire terminal of transmission inhibitor switch. If voltage does not exist at inhibitor switch Black/Yellow wire terminal, check for voltage to ignition switch BAT terminal and from ignition switch START terminal to inhibitor switch Black/Yellow wire terminal. If voltage does not exist, repair wiring as required or replace ignition switch.

Loyale M/T

1. Turn ignition switch to START position, press clutch pedal to floor and check for near battery voltage at starter solenoid terminal No. 50 (Black/White wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at clutch switch Black/White wire terminal when clutch pedal is pressed to floor.
2. Clutch switch is located at top of clutch pedal arm. If voltage exists at Black/White wire terminal of clutch switch, repair wiring between clutch switch and starter. If voltage does not exist, check for voltage at Black/Yellow wire terminal of clutch switch. If voltage exists, replace clutch switch.
3. If voltage does not exist at Black/Yellow wire terminal of clutch switch, check for near battery voltage at ignition switch "S" terminal (Black/Yellow wire). If voltage exists, repair Black/Yellow wire between ignition switch and clutch switch.
4. If voltage does not exist at ignition switch "S" terminal (Black/Yellow wire), check for battery voltage at ignition switch battery terminal. If voltage does not exist, replace ignition switch.

XT & XT6 (A/T)

1. Ensure gear select lever is in Park or Neutral. Turn ignition switch to START position and check for near battery voltage at starter solenoid "S" terminal (Black/Yellow wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at inhibitor switch Black/Yellow wire terminal.
2. Inhibitor switch is located on transmission lever. If voltage exists at inhibitor switch Black/Yellow wire terminal, repair wiring to starter. If voltage does not exist, check for voltage from ignition switch to inhibitor switch Black/White wire terminal.
3. If voltage exists at inhibitor switch Black/White wire terminal, replace inhibitor switch. If voltage does not exist, check for voltage at ignition switch "S" terminal (Black/White wire). If voltage exists here, repair Black/White wire between ignition switch and inhibitor switch. If voltage does not exist at ignition switch "S" terminal, replace ignition switch.

XT & XT6 (M/T)

1. Turn ignition switch to START position, press clutch pedal to floor and check for near battery voltage at starter solenoid "S" terminal (Black/Red wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at interlock relay terminal No. 3 (Black/Red wire). (Scheme 1)
2. Interlock relay has a Blue 4-terminal connector and is located behind center console, above radio. When clutch pedal is pressed to floor, clutch switch grounds interlock relay terminal No. 1 (Green/Yellow wire), which energizes interlock relay. Clutch switch is located at top of clutch pedal arm.
3. If voltage exists at interlock relay terminal No. 3 (Black/Red wire), repair wiring to starter. If voltage does not exist, check for near battery voltage at interlock relay terminals No. 2 and 4 (Black/White wires) when ignition switch is turned to START position. (Scheme 1) If voltage exists at relay terminals No. 2 and 4, go to step 5).
4. If voltage does not exist at relay terminals No. 2 and 4, check for voltage to ignition switch BAT terminal and from ignition switch START terminal. Repair wiring or replace switch as required. If voltage exists at START terminal, repair Black/White wiring between ignition switch and interlock relay terminals No. 2 and 4.
5. If voltage exists at relay terminals No. 2 and 4, ground interlock relay terminal No. 1 (Green/Yellow wire) using jumper wire. Check for near battery voltage at relay terminal No. 3 (Black/Red wire). If voltage exists, replace clutch switch. If voltage does not exist, replace relay.

SVX

1. Ensure gear select lever is in Park or Neutral position. Turn ignition switch to START position and check for near battery voltage at starter solenoid terminal "S" (Black/Yellow wire). If near battery voltage exists and starter does not crank, repair or replace starter. If voltage does not exist, check for voltage at inhibitor switch Black/Yellow wire terminal.
2. Inhibitor switch is located on transmission lever. If voltage exists at inhibitor switch Black/Yellow wire terminal, repair wiring to starter. If voltage does not exist, check for voltage from ignition switch to inhibitor switch Black/White wire terminal.
3. If voltage exists at inhibitor switch Black/White wire terminal, replace inhibitor switch. If voltage does not exist, check for voltage at ignition switch terminal "S" (Black/White wire). If voltage exists, repair Black/White wire between ignition switch and inhibitor switch. If voltage does not exist at ignition switch terminal "S", replace ignition switch.

Legacy M/T

1. Interlock relay has a Blue 4-terminal connector and is located on brake pedal bracket, next to brakelight switch. Locate and unplug relay.
2. Connect test light to terminal No. 3 (Red/Yellow wire) of interlock relay. (Scheme 1) Using jumper wire, apply 12 volts to terminals No. 2 and 4 (Blue/Red wires) of relay. Using another jumper wire, connected to ground, momentarily touch terminal No. 1 (Green/Yellow wire) of relay. If test light does not illuminate, replace relay.

XT M/T

1. Interlock relay has a Blue 4-terminal connector and is located behind center console, above radio. Clutch switch is located at top of clutch pedal arm.
2. Connect test light to terminal No. 3 (Black/Red wire) of interlock relay. (Scheme 1) Using jumper wire, apply 12 volts to terminals No. 2 and 4 (Black/White wires) of relay. Using another jumper wire, connected to ground, momentarily touch terminal No. 1 (Green/Yellow wire) of relay. Test light should illuminate. If test light does not illuminate, replace relay.

Start Circuit Test

1. Remove lower instrument panel below steering wheel. Remove air duct. Remove harness connector from rear of ignition switch.
2. Using jumper wire, apply 12 volts to ignition switch terminal "B". Connect test light to switch terminal "S". Turn ignition switch to START position. If test light does not illuminate, replace relay.

Continuity Test

Ensure continuity is as specified. See IGNITION SWITCH CONTINUITY SPECIFICATIONS table. (Scheme 2) Repair or replace as necessary.

IGNITION SWITCH CONTINUITY SPECIFICATIONS

Scheme 2

BENCH TESTING

NO-LOAD TEST

1. Clamp starter in bench tester or in vise. Connect test equipment to starter. (Scheme 3) Close switch to engage starter. Measure current draw, rotating speed and voltage drop. See «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table at end of article.
2. Low rotating speed or excessive current draw may be caused by high friction rotating resistance caused by worn bushings or improper assembly.

Scheme 3

LOAD TEST

1. Using proper starter bench tester, connect test equipment and apply specified load to starter. See «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table at end of article. Engage tester switch for less than 30 seconds. Note and record voltage drop and current draw.
2. Voltage should not drop to less than 8 volts. On A/T models, current draw should be less than 370 amps and rotating speed should be greater than 880 RPM. On M/T models, see «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table.

LOCK TEST

1. Using proper starter bench tester, connect test equipment and lock starter armature. Engage tester momentarily while measuring starter torque, current draw and voltage drop.
2. Check specifications for minimum torque, voltage drop (minimum volts) and current draw (maximum amps). See «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table at end of article.
3. Low current draw and no torque during lock test may be caused by excessive resistance between brushes and commutator. Normal current draw but low torque speed may be caused by a shorted commutator and/or poor insulation.

ARMATURE TEST

1. With starter disassembled, check armature for shorts using a growler. Hold hacksaw blade against armature while slowly rotating armature. A shorted armature will cause hacksaw blade to vibrate when passed over shorted area. Replace as necessary.
2. Use an ohmmeter to check for grounded armature. Touch one probe to each segment of commutator and hold other probe to armature core. If continuity exists, replace armature.
3. Use ohmmeter to check for open circuit. If continuity is not present between any 2 commutator segments, replace armature. Check commutator for outside diameter wear, runout and mica insulation depth. See «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table at end of article.
4. If correcting runout condition, DO NOT reduce armature size beyond specification. Undercut mica insulation if it is even or higher than commutator surface. (Scheme 4) See «STARTER SPECIFICATIONS»(/subaru/legacy/bcbjbf-1989-1994/remont/starter/#starter-reduction-gear) table.

Scheme 4

BRUSH HOLDER TEST

Check condition of brush holder springs, spring clip and insulation between positive and negative holders. Continuity should not exist between brush holder and holder plate. Repair or replace as needed.

FIELD COIL TEST

Check for open circuits in field coils of yoke assembly. Continuity should exist between lead wire and field coil brush lead. If continuity does not exist, replace field coil. Check for continuity between field coils and yoke assembly (end frame). If continuity exists, field coil is shorted to ground. Replace field coil.

OVERRUNNING CLUTCH TEST

Ensure pinion rotates smoothly in direction of rotation. Pinion should not rotate in opposite direction. Inspect teeth for excessive wear and damage. Replace as necessary.

Shunt Coil Test (XT & XT6)

Ensure continuity exists between solenoid terminal "S" and solenoid body (ground). Ensure continuity exists between solenoid terminals "M" and "S". If continuity does not exist, solenoid is open and requires replacement.

Contact Continuity Test (XT & XT6)

Continuity should exist between terminal "M" and terminal "B" with solenoid plunger pushed in. If continuity does not exist, replace solenoid.

Solenoid Pull-In Test (Legacy & Loyale)

Connect 2 jumper wires from negative terminal of 12-volt battery to starter solenoid case and to terminal "C". (Scheme 5) Pinion should extend when jumper wire from battery positive terminal is connected to solenoid terminal No. 50. If pinion does not extend as specified, replace starter.

Scheme 5

Solenoid Hold-In Test (Legacy & Loyale)

Disconnect jumper wire from solenoid terminal "C" with pinion extended. Pinion should remain extended. If pinion does not remain extended, replace starter.

Pinion Gear Return Test (Legacy & Loyale)

Connect 2 jumper wires from negative terminal of 12-volt battery to starter solenoid case and to terminal No. 50. (Scheme 6) Momentarily touch positive jumper wire to terminal "C". Pinion gear should return immediately. If pinion gear does not return immediately, replace starter.

Scheme 6

STARTING SYSTEM

STARTING SYSTEM TROUBLE SHOOTING

BYPASSING ANTI-THEFT SYSTEM STARTER INTERRUPT (SVX ONLY)

Vehicle anti-theft system has a starter interrupt feature which can be turned off or bypassed to enable the vehicle to be started conventionally. To deactivate anti-theft system, use appropriate button on remote transmitter. If transmitter is lost or not functioning properly, the following procedure must be used.

Enter vehicle, (this should cause the alarm system to sound), and completely close the door. Do not touch the security switch or open any of the doors or trunk. Turn parking lights ON, and start engine. Turn parking lights OFF.

OVERHAUL

Note. Overhaul procedures not available at time of publication. For exploded view of starter (Scheme 7), (Scheme 8) or (Scheme 9).

Scheme 7

Scheme 8

Scheme 9

Scheme 10

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS (LEGACY)

STARTER SPECIFICATIONS (LOYALE)

STARTER SPECIFICATIONS (SVX)

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• IGNITION SWITCH CONTINUITY SPECIFICATIONS
• BYPASSING ANTI-THEFT SYSTEM STARTER INTERRUPT