Starting System & Charging System (Except Wrx): Diagnosis Subaru XV GP

PERFORMANCE TEST

The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine.

Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test.

For these performance tests, use the circuit shown in figure.

Scheme 5

1. Adjust the variable resistance with the switch on until the voltage is 11 V, and read the value displayed by the ammeter to measure starter speed. Compare these values with the standard. No-load test (standard): Voltage/Current CVT model Max. 11 V/90 A or less MT model Max. 11 V/95 A or less Rotating speed CVT model 2, 370 rpm or more MT model 2, 500 rpm or more
2. Apply the specified braking torque to starter. The condition is normal if the current draw and starter speed are within standard. Load test (standard): Voltage/Load CVT model 7.5 V/10.65 N.m (1.1 kgf-m, 7.8 ft-lb) MT model 7.5 V/8.84 N.m (0.9 kgf-m, 6.5 ft-lb) Current/Speed CVT model 300 A/840 rpm or more MT model 300 A/870 rpm or more
3. With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to standard voltage. Lock test (standard): Voltage/Current CVT model 4 V/780 A or less MT model 4 V/680 A or less Torque CVT model 20 N.m (2.0 kgf-m, 14.8 ft-lb) or more MT model 17 N.m (1.7 kgf-m, 12.5 ft-lb) or more

OTHER INSPECTIONS

Check that the starter does not have deformation, cracks and any other damage.

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1. Remove the V-belt covers.
2. Disconnect the ground cable from battery.
3. Remove the V-belts. < Refer to «REMOVAL»(ref-560356-S39091804112013061300000) , V-belt. >
4. Remove the V-belt cover bracket.
5. Disconnect the connector (A) and terminal (B) from the generator.
6. Remove the idler pulley from the chain cover.
7. Remove the generator from the bracket.
8. Remove the generator bracket from the generator.

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1. Temporarily install the generator bracket to the generator.
2. Temporarily install the generator to the engine.
3. Tighten the generator and generator bracket in the numerical order. Tightening torque: T1: 25 N.m (2.5 kgf-m, 18.4 ft-lb) T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
4. Install the V-belt cover bracket and tighten the bolts in the numerical order. Tightening torque: T1: 8.5 N.m (0.9 kgf-m, 6.3 ft-lb) T2: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
5. Install the idler pulley to the chain cover. Tightening torque: 36 N.m (3.7 kgf-m, 26.6 ft-lb)
6. Connect the connector (A) and terminal (B) to the generator. Tightening torque: 16 N.m (1.6 kgf-m, 11.8 ft-lb)
7. Install the V-belts. < Refer to «INSTALLATION»(ref-560356-S41858146502013061300000) , V-belt. >
8. Connect the battery ground terminal.
9. Install the V-belt cover. Tightening torque: 13 N.m (1.3 kgf-m, 9.6 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 flat tip screwdriver into the gap between stator core and front cover 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 which connect 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.

INSPECTION