Starting System & Charging System (H4SO): Removal & Installation Subaru Outback BR

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)

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

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1. Remove the nut which holds terminal M (A) of the magnet switch assembly, then disconnect the harness from the terminal.
2. Remove the nuts fastening the magnet switch assembly to the starter housing, then remove the magnet switch assembly.
3. Remove the starter seal.
4. Remove the through bolts on both sides, and remove the starter housing.
5. Remove the shift lever.
6. Remove the overrunning clutch, shock absorber bearing, and shaft from the yoke as a single unit
7. Use the following procedures to remove the overrunning clutch from the shaft assembly. Use an appropriate tool (such as a fit socket wrench), 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.
8. Remove the shock absorber in the following procedures: Remove the starter plate. Remove the planetary gear. Remove the snap ring, then remove the shaft. Separate shock absorber bearing (A) from internal gear (B), and remove shock absorber (C).
9. Remove the screws, and remove the starter cover from the brush holder assembly. NOTE: Separate the starter cover by pressing the brush holder assembly using the screws so that the assembly stays onto the armature side.
10. Remove the brush holder assembly from the armature. NOTE: Expand the brush with your fingers while taking care not to scratch it.
11. Remove the armature from the yoke.

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1. Install the armature to the yoke.
2. Install the brush holder assembly to the armature. NOTE: Expand the brush with your fingers while taking care not to scratch it.
3. Install the starter cover, and secure it to the brush holder assembly with the screws.
4. Assemble the shock absorber in the following procedures: Apply grease to shock absorber (C), and assemble internal gear (B) to shock absorber bearing (A). NOTE: Align with the claw position of internal gear to assemble the shock absorber bearing. Grease: DENSO HL50 Assemble the shaft to the internal gear. NOTE: Apply grease to the shaft sliding surfaces inside the internal gear. Grease: DENSO HL50 Attach the snap ring to the shaft. NOTE: Use new snap rings.
5. Assemble the planetary gear to the internal gear. Apply grease to the planetary gear installation position. Grease: DENSO HL50 Install the planetary gear to the pin. Apply grease to the planetary gear, internal gear, and upper part of the pin. NOTE: Apply grease so that it contact surfaces of each gear. Be careful not to allow dirt to get in. Grease: DENSO HL50 Install the starter plate.
6. Assemble the overrunning clutch as follows: Apply grease to the spline portion of the shaft. Grease: DENSO HL50 Install the overrunning clutch to shaft. Install stopper (B) to the shaft, then install snap ring (A). Using a press, pressure fit stopper (B) into snap ring (A).
7. Assemble the overrunning clutch, shock absorber, and shaft to the yoke as a single unit
8. Install the shift lever. NOTE: Apply grease to the contact area of the shift lever. Grease: DENSO HL50
9. Install the starter housing, and tighten through bolts on both sides. Tightening torque: 6 N.m (0.6 kgf-m, 4.4 ft-lb)
10. Install the starter seal.
11. Install the magnet switch assembly to the starter housing, and tighten the nuts. NOTE: Apply grease to the shift lever installation position. Grease: DENSO HL50 Tightening torque: 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
12. Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut. Tightening torque: 10 N.m (1.0 kgf-m, 7.4 ft-lb)

Install in the reverse order of removal.

Tightening torque

T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb)

T2: 6.4 N.m (0.7 kgf-m, 4.7 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 terminal B. Remove the nuts of terminal B, then remove the rectifier.

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1. Remove the four through bolts.
2. Use a drier to heat the rear cover (A) portion to 50 - 60°C(122 - 140°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. Remove six bolts between the rectifier and stator coil, then remove the stator coil.
8. Remove four screws which secure the IC regulator to the rear cover, 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 cover on terminal B. Remove the nut on terminal B. Remove the bolts which secure the rectifier, and 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. Wait for 10 seconds or more after turning the ignition switch to ON, and then start the engine.