Starting System & Charging System (H6DO): Removal & Installation Subaru Outback BS

INSTALLATION

Install in the reverse order of removal.

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)

Scheme 15

Tightening torque

Clamp (A) 3 N.m (0.3 kgf-m, 2.2 ft-lb)

Bolt (B) 6.5 N.m (0.7 kgf-m, 4.8 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 assembly from the yoke.
7. Remove the starter plate.
8. Remove the planetary gear (A) and washer (B) from internal gear.
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: Spread the brush with your fingers, being careful not to damage the brush.
11. Remove the armature from the yoke.

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 - 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 nut, then remove the rotor from the front cover. 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 positive (+) terminal, and then connect the negative (-) terminal of the battery. 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.