Starter 2.5L: Diagnosis Subaru Outback BH

TROUBLE SHOOTING

Note. See TROUBLE SHOOTING article in GENERAL INFORMATION.

BENCH TESTING

NO-LOAD TEST

1. Clamp starter in starter bench tester. Connect test equipment to starter. (Scheme 4) Close switch to engage starter. Measure current draw, rotating speed, and voltage drop. See «STARTER SPECIFICATIONS»(ref-121721-S24266779022001090500000). Repair or replace starter if performance is not as specified.
2. Low rotating speed or excessive current draw may be caused by high friction rotating resistance because of worn bushings or improper assembly.

Scheme 4

LOAD TEST

Using starter bench tester, connect test equipment and apply specified load to starter. Engage tester switch for less than 30 seconds. Note and record voltage drop and current draw. See STARTER SPECIFICATIONS . Repair or replace starter if performance is not as specified.

LOCK TEST

1. Using 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»(ref-121721-S24266779022001090500000) .
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. Repair or replace starter if performance is not as specified.

ARMATURE TEST

1. Check armature for short using a growler and hacksaw blade. Hold hacksaw blade against armature while slowly rotating armature in growler. A shorted armature will cause hacksaw blade to vibrate and be attracted to armature core when passed over shorted area. Replace armature 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 commutator for open circuit. If continuity does not exist between any 2 commutator segments, replace armature. Check commutator for outside diameter wear, runout and mica insulation depth. See «STARTER SPECIFICATIONS»(ref-121721-S24266779022001090500000).
4. If correcting runout condition, DO NOT reduce commutator diameter below specification. Undercut mica insulation if it is even with or higher than commutator surface. (Scheme 5) See «STARTER SPECIFICATIONS»(ref-121721-S24266779022001090500000).

Scheme 5

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 holder 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 overrunning clutch as necessary.

Solenoid Pull-In Test (Impreza & Forester)

Connect jumper wire from terminal "S" and positive battery terminal. Connect another jumper wire from negative battery terminal to starter body. Pinion should extend when jumper wire from battery negative terminal is connected to starter body. If pinion does not extend, replace starter.

Pinion Gap Test (Impreza & Forester)

Disconnect connector from terminal "M" of solenoid. Connect a jumper wire between terminal "M" and negative battery terminal. With pinion extended, use a feeler gauge to measure gap between pinion gear and stopper. Ensure pinion gap is .020-.079" (0.5-2.0 mm). If pinion gap is not as specified, remove or add adjustment washers until correct gap is obtained.

Pinion Gear Return Test (Impreza & Forester)

Disconnect connector from terminal "M". Connect a jumper wire from terminal "M" to positive battery terminal. Ensure pinion returns to its original position when pulled out with a screwdriver.

Solenoid Pull-In Test (Legacy & Outback)

Connect jumper wire from negative battery terminal to starter solenoid case. Connect another jumper wire from negative battery terminal to starter solenoid terminal "C". (Scheme 6) 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 6

Solenoid Hold-In Test (Legacy & Outback)

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 & Outback)

Connect jumper wire from battery negative terminal to starter solenoid case. Connect another jumper wire from battery negative terminal to starter solenoid terminal No. 50. (Scheme 7) Momentarily touch positive jumper wire to starter solenoid terminal "C". Pinion gear should return immediately. If pinion gear does not return immediately, replace starter.

Scheme 7

Scheme 8

Scheme 9

Scheme 10

1. Disconnect battery ground cable. (Scheme 8): Disconnecting Battery Ground Cable
2. Remove air cleaner case, see «AIR CLEANER»(ref-121721-S22491470682005050200000)
3. Disconnect connector and terminal from starter. (Scheme 9): Disconnecting Connector And Terminal From Starter
4. Remove starter from transmission. (Scheme 10): Removing Starter From Transmission