SUBARU FORESTER 2004 Service Repair Manual

SC(H4SO)-6
STARTING/CHARGING SYSTEM
Starter
2. Starter
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. (Non-turbo model)
<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
3) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-10, REMOVAL, Intercooler.>
4) Remove the air cleaner case stay. (Non-turbo
model)
 MT model
 AT model5) Disconnect the connector and terminal from
starter.
6) Remove the starter from transmission.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 37 ft-lb)
FU-00009
SC-00004
SC-00005
(A) Terminal
(B) Connector
SC-00006
SC-00007
SC-00007

SC(H4SO)-7
STARTING/CHARGING SYSTEM
Starter
C: DISASSEMBLY
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.
2) Remove the bolts which hold switch assembly,
and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
NOTE:
Be careful because the pinion gap adjustment
washer may sometimes be used on the mounting
surface of switch assembly.
3) Remove both the nuts, and then remove rear
cover set.4) Remove both through-bolts and brush holder
screws, and then detach the rear cover and brush
holder assembly.
5) Remove the armature and yoke assembly from
front bracket.
6) Remove the packing A, planetary gear and
packing B.
(A) Terminal M
(A) Switch ASSY
(A) Rear cover set
SC-00059
(A)
SC-00060
(A)
SC-00061
(A)
(A) Brush holder ASSY
(B) Rear cover
(A) Armature
(B) Yoke ASSY
(C) Front bracket
(A) Packing A
(B) Planetary gear
(C) Packing B
SC-00062
(A)
(B)
(A) (B)
(C)
SC-00063
SC-00064
(A)
(C)
(B)

SC(H4SO)-8
STARTING/CHARGING SYSTEM
Starter
7) Remove the plate.
8) Remove the shaft assembly and overrunning
clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
 Lever direction
 Position of internal gear assembly
9) Remove the overrunning clutch from shaft as-
sembly as follows:
(1) Remove the stopper from ring by lightly tap-
ping the stopper with an appropriate tool (such
as a 14 mm (0.55 in) a fit socket wrench).(2) Remove the ring, stopper and clutch from
shaft.
(A) Plate
(A) Lever
(B) Shaft ASSY
(C) Overrunning clutch
(D) Internal gear ASSY
SC-00065
(A)
SC-00066
(A)
(D)
(C) (B)
(A) Socket wrench
(B) Ring
(C) Shaft
(D) Stopper
SC-00014

SC(H4SO)-9
STARTING/CHARGING SYSTEM
Starter
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assem-
bly.
 Sleeve bearing
 Pinion shaft rotational portion
 Shaft spline portion
 Inside of reduction system
 Lever fulcrum/Clutch rotational portion
1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.
(1) Insert the ring into the shaft groove by lightly
tapping it with an appropriate tool (such as a fit
socket wrench).
(2) Install the stopper to ring using a press.
3) Install the shaft assembly to front bracket while
taking care of the following points.
(1) Lever direction(2) Internal gear position
4) Install the plate.
5) Install the planetary gear.
6) Install packing A and B while taking care of in-
stalling positions.
7) Install the armature to yoke assembly.
(A) Ring
(B) Stopper
SC-00067
(B)(A)
SC-00068
(A)
(B)
SC-00069
(A) Plate
(A) Packing A
(B) Packing B
SC-00070
SC-00065
(A)
SC-00071
(A)
(B)

SC(H4SO)-10
STARTING/CHARGING SYSTEM
Starter
8) Install the yoke to front bracket matching front
bracket to groove of yoke assembly.
9) Install the brush holder to yoke assembly as fol-
lows.
(1) Press the brush down into brush holder, and
then fix the brush in that position using an appro-
priate tool (such as a fit socket wrench).
(2) Match the brush holder to groove of yoke,
and then slide the brush holder into yoke assem-
bly to install.10) Install the rear cover matching it’s groove to
brush holder assembly.
11) Install rear cover set.
12) Install the switch assembly to front bracket as
follows.
(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.
SC-00072
SC-00073
SC-00074
(A) Brush holder ASSY
(B) Rear cover
(A) Rear cover set
(A) Switch ASSY
SC-00062
(A)
(B)
SC-00061
(A)
SC-00060
(A)

SC(H4SO)-11
STARTING/CHARGING SYSTEM
Starter
13) Connect the connector to terminal M of switch
assembly.
E: INSPECTION
1. ARMATURE
1) Check the commutator for any sign of burns of
rough surfaces or stepped wear. If wear is of a mi-
nor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out, and then replace if
it exceeds the limit.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)
3) Depth of segment mold
Check the depth of segment mold.Depth of segment mold:
0.5 mm (0.020 in)
4) Armature short-circuit test
Check the armature for short-circuit by placing it on
growler tester. Hold a iron sheet against the arma-
ture core while slowly rotating armature. A short-
circuited armature will cause the iron sheet to vi-
brate and to be attracted to core. If the iron sheet is
attracted or vibrates, the armature, which is short-
circuited, must be replaced or repaired.
5) Armature ground test
Using a circuit tester, touch one probe to the com-
mutator segment and the other to shaft. There
should be no continuity. If there is continuity, the ar-
mature is grounded.
Replace the armature if it is grounded.
(A) Terminal M
(A) Dial gauge
(B) V-block
SC-00059
(A)
SC-00021
(A) Depth of mold
(B) Segment
(C) Mold
(A) Iron sheet
(B) Grower tester
(A) (B)
(C)
SC-00022
(A)
(B)
SC-00023
SC-00024

SC(H4SO)-12
STARTING/CHARGING SYSTEM
Starter
2. YOKE
Make sure the pole is set in position.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in direc-
tion of rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length
Measure the brush length, and then replace if it ex-
ceeds the service limit.
Replace if abnormal wear or cracks are noticed.
Brush length:
Standard
12.3 mm (0.484 in)
Service limit
7.0 mm (0.276 in)
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between the terminals S
and M, and between terminal S and ground. Use a
circuit tester (set in “ohm”).
Also check to be sure there is no continuity be-
tween terminal M and B.
Terminal / Specified resistance:
S — M / Less than 1
Ω
S — Ground / Less than 1 Ω
M — B / More than 1 MΩ
6. SWITCH ASSEMBLY OPERATION
1) Connect the terminal S of switch assembly to
positive terminal of battery with a lead wire, and
starter body to ground terminal of battery. The pin-
ion should be forced endwise on shaft.
CAUTION:
With the pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.
2) Disconnect the connector from terminal M, and
then connect the positive terminal of battery and
terminal M using a lead wire and ground terminal to
starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(A) Service limit line
(B) Brush
SC-00102
(A)
(B)
(A) Terminal S
(B) Terminal M
SC-00075
B
M
S
SC-00076
(B) (A)

SC(H4SO)-13
STARTING/CHARGING SYSTEM
Starter
7. PINION GAP
1) Measure the pinion gap while the pinion is pulled
out as shown in the figure.
Pinion gap:
0.5 — 2.0 mm (0.020 — 0.079 in)
If the motor is running with the pinion forced end-
wise on shaft, disconnect the connector from termi-
nal M of switch assembly, and then connect
terminal M to ground terminal (−) of battery with a
lead wire. Next, gently push the pinion back with
your fingertips, and then measure the pinion gap.
2) If the pinion gap is outside specified range, re-
move or add number of adjustment washers used
on the mounting surface of switch assembly until
correct pinion gap is obtained.
8. 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.
1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading, and then mea-
sure the starter speed. Compare these values with
the specifications.
No-load test (Standard):
Voltage / Current
MT model
MAX. 11 V / 95 A
AT model
MAX. 11 V / 90 A
Rotating speed
MT model
2,500 rpm or more
AT model
2,000 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
Load test (Standard):
Voltage / Load
MT model
7.5 V / 8.84 N (0.90 kgf, 1.99 lb)
AT model
7.7 V / 16.7 N (1.70 kgf, 3.75 lb)
(A) Pinion
(B) Pinion gap
(C) Stopper
SC-00027
(A) Variable resistance
(B) Starter body
(C) Magnetic switch
SC-00077
(A) (B)
(C)
12V +
AV
BS
M

SC(H4SO)-14
STARTING/CHARGING SYSTEM
Starter
Current / Speed
MT model
300 A / 870 rpm or more
AT model
400 A / 710 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage / Current
MT model
4 V / 680 A or less
AT model
3.5 V / 960 A or less
Torque
MT model
17.0 N (1.73 kgf, 3.82 lb) or more
AT model
31.0 N (3.16 kgf, 6.97 lb) or more

SC(H4SO)-15
STARTING/CHARGING SYSTEM
Generator
3. Generator
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector and terminal from
generator.
 Non-turbo model
 Turbo model
3) Remove the V-belt cover.
 Non-turbo model Turbo model
4) Remove the front side V-belt.
<Ref. to ME(H4SO)-43, FRONT SIDE BELT, RE-
MOVAL, V-belt.> or <Ref. to ME(H4DOTC)-52,
FRONT SIDE BELT, REMOVAL, V-belt.>
5) Remove the bolts which install generator onto
bracket.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Check and adjust the V-belt tension. <Ref. to
ME(H4SO)-44, INSPECTION, V-belt.> or <Ref. to
ME(H4DOTC)-53, INSPECTION, V-belt.>
FU-00009
SC-00029
SC-00143
SC-00031
SC-00096
SC-00032
SC-00032