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

CAUTION

1. Prior to starting work, pay special attention to the following: Always wear work clothes, a safety cap, protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary. Protect the vehicle using a seat cover, fender cover, etc. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
2. Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
3. When performing a repair, identify the cause of trouble and avoid unnecessary removal, disassembly and replacement.
4. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from battery.
5. Always use the jack-up point when the shop jacks or rigid racks are used to support the vehicle.
6. Remove contamination including dirt and corrosion before removal, installation, disassembly or assembly.
7. Keep the removed parts in order and protect them from dust and dirt.
8. All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
9. Bolts, nuts and washers should be replaced with new parts as required.
10. Be sure to tighten the fasteners including bolts and nuts to the specified torque.

GENERAL TOOL

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1. Disconnect the ground cable from battery.
2. Remove the clip (A) from the air intake boot.
3. Loosen the clamp (B) connecting the air intake boot and air cleaner case (rear).
4. Loosen the clamp (C) which connects the air intake boot and throttle body.
5. Remove the air intake boot from the throttle body, and move the air intake boot to the left side wheel apron.
6. Disconnect the connector (B) and terminal (A) from starter.
7. Remove the starter from transmission. NOTE: For CVT model, a nut is used at (A).

YOKE

Make sure that the pole is set at the predetermined position.

OVERRUNNING CLUTCH

Inspect the pinion, and if there is any wear or damage, replace the overrunning clutch. Also, check that the pinion rotates counterclockwise smoothly and does not rotate clockwise. If there is any fault, replace the overrunning clutch.

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1. Visually check the brush. If there is any abnormal wear or cracks, replace the brush.
2. Measure the length of the brush. If it exceeds service limits, replace the brush. Brush length: Standard 12.3 mm (0.484 in) Limit 7.0 mm (0.276 in)
3. Check that the brush moves smoothly in the brush holder.
4. Measure the brush spring force with a spring scale. Replace the brush holder if below the service limit. Brush spring force: Standard 15.9 - 19.5 N (1.62 - 1.99 kgf, 3.57 - 4.38 lbf) (When new) Limit 2.5 N (0.25 kgf, 0.56 lbf)

DIODE

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1. Check for continuity between the diode lead and terminal E or B. If continuity is not as shown in the table, replace the rectifier. At analog type tester Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 Yes B No P1, P2, P3, P4, P5, P6 E No B Yes At digital type tester Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 No B Yes P1, P2, P3, P4, P5, P6 E Yes B No

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1. Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper.
2. Slip ring outer diameter Measure the slip ring outer diameter. Replace the rotor if the slip ring is worn. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Limit 22.1 mm (0.870 in)
3. Continuity test Using a circuit tester, check the resistance between slip rings. If the resistance is not within the standard, replace the rotor. Standard: Approx. 2.0 - 2.4 ohms
4. Insulation test Check the continuity between slip ring and rotor core or shaft. If there is continuity, replace the rotor because the rotor coil is grounded.
5. Bearing Check the bearings. If there is any noise, or the rotor does not rotate smoothly, replace the bearings.

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1. Continuity test Inspect the continuity between the stator coil terminals. If continuity is not as shown in the table, replace the stator coil.
2. Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If there is continuity, replace the stator coil because the stator coil is grounded.

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1. Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush. Brush length: Standard (1) 18.5 mm (0.728 in) Limit (2) 5.0 mm (0.197 in)
2. Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.0787 in). Then measure the pressure of brush spring. If the pressure is 1.7 N (173 gf, 6.11 ozf) or less, replace the brush spring. 4.1 - 5.3 N (418 - 540 gf, 14.75 - 19.06 ozf) pressure is required on the new spring.

BALL BEARING

Check the ball bearings. Replace the ball bearings if there is resistance in the rotation, or if there is any abnormal noise.

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1. Disconnect the positive (+) terminal after disconnecting the negative (-) terminal of battery.
2. Remove the battery cable holder from the battery rod.
3. Remove the flange nut from battery rod and remove battery holder.
4. Remove the battery.

EXTERNAL PARTS

Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth.

Apply a thin coat of grease on the terminal posts to prevent corrosion.

ELECTROLYTE LEVEL

Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX level.

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1. Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following calculation: S 20 = St + 0.0007 x (t - 20) S 20 : Specific gravity corrected at electrolyte temperature of 20°C St: Measured specific gravity t: Measured temperature (°C) Judge whether or not the battery requires charging according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20°C (68°F)]
2. Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.

MEASUREMENT

JUDGMENT OF BATTERY IN CHARGED CONDITION

1. Specific gravity of electrolyte should be held within the specific range of 1.250 - 1.290 for one hour or more.
2. Voltage per battery cell should be held at a specific value in a range of 2.5 - 2.8 V for one hour or more.

CHECK CONDITION OF CHARGE WITH HYDROMETER

NORMAL CHARGING

Charge the battery at the current value specified by manufacturer or at approximately 1/10 of battery's ampere-hour rating.

QUICK CHARGING

Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger.

Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, quick charging must be carried out within a current range that will not raise the electrolyte temperature to 40°C (104°F) or more.

Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule.

BATTERY CURRENT SENSOR

Note. Remove the battery current sensor and battery cable as a unit.

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1. Disconnect the battery ground cable and remove the clip from the battery rod.
2. Remove the battery terminal boot.
3. Remove the nuts, and then remove the terminal fuse assembly.
4. Remove the ground terminal from the vehicle and remove the harness clip.
5. Disconnect the harness connector (A) from the battery cable.
6. Remove the battery cable clip (B) from the battery cable bracket.
7. Remove the clip (A) from the air intake boot.
8. Loosen the clamp (B) connecting the air intake boot and air cleaner case (rear).
9. Loosen the clamp (C) which connects the air intake boot and throttle body.
10. Remove the air intake boot from the throttle body, and move the air intake boot to the left side wheel apron.
11. Remove the terminal B (A) from the starter.
12. Remove the starter ground cable (B) and remove the battery cable.

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1. Remove the battery. < Refer to «REMOVAL»(ref-560379-S28864293722013061300000) , Battery. >
2. Remove the clip, and remove the battery temperature sensor from the bracket.
3. Disconnect the connector and remove the battery temperature sensor.

Install in the reverse order of removal.

Tightening torque

< Refer to BATTERY CURRENT & TEMPERATURE SENSOR , COMPONENT, General Description. >

BATTERY TEMPERATURE SENSOR

Install in the reverse order of removal.

Check the resistance between the battery current sensor terminals.

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Check the resistance between the battery temperature sensor terminals.

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