Starting System & Charging System (H4SO): Overhaul Subaru Outback BR

SWITCH ASSEMBLY

Using a circuit tester (set to "ohm"), check that there is continuity between terminals S and M, and between terminal S and ground.

Also check to be sure there is no continuity between terminals M and B.

Terminal/Resistance

S - M/1 ohms or less

S - Ground/1 ohms or less

M - B/1 Mohms or more

Scheme 58

ASSEMBLY

Assemble in the reverse order of disassembly.

Note. Refer to component for tightening torque of each part. Ref. to GENERATOR , COMPONENT, General Description.

Scheme 59

1. Push of the brush Before assembling the front and rear parts, press the brush down into the brush holder, then fix the brush in that position by inserting a [1 mm (0.08 in) dia., 40 - 50 mm (1.6 - 2.0 in) long] wire through the hole as shown in the figure. CAUTION: After re-assembling, remove the wire.
2. Install the ball bearings. Set the ball bearings in the front cover, then securely install an appropriate tool (such as a socket wrench of proper size) to the bearing outer race. Using a press to press the ball bearings into the specified location. Install the bearing retainer.
3. Use a press to install the bearings (rear side) to the rotor shaft.
4. Heat the bearing box in rear cover to 50 - 60°C (122 - 140°F), and then press the rear bearing into rear cover. CAUTION: Do not apply grease to the rear bearings. If there is any oil on the bearing box, remove it completely.
5. After re-assembling, manually turn the pulley to check that the rotor rotates smoothly.