charging SUBARU FORESTER 2004 Service Owner's Manual

FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)

FUJI HEAVY INDUSTRIES LTD. G8080GE2
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.FUEL INJECTION (FUEL SYSTEM) FU(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEM SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEM SC(H4SO)
ENGINE (DIAGNOSTIC) EN(H4SO)

STARTING/CHARGING SYSTEM
SC(H4SO)
Page
1. General Description ....................................................................................2
2. Starter .........................................................................................................6
3. Generator ..................................................................................................15
4. Battery .......................................................................................................21

SC(H4SO)-2
STARTING/CHARGING SYSTEM
General Description
1. General Description
A: SPECIFICATION
Item Designation
StarterType Reduction type
Vehicle type MT model AT model
Model M000T30471 M000T20171
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (viewed from pinion gear side)
Number of pinion teeth 8 9
No-load charac-
teristicsVo l t a g e 1 1 V
Current 95 A or less 90 A or less
Rotating speed 2,500 rpm or more 2,000 rpm or more
Load character-
isticsVoltage 7.5 V 7.7 V
Current 300 A 400 A
Torque 8.84 N (0.90 kgf, 1.99 lb) or more 16.7 N (1.70 kgf, 3.75 lb) or more
Rotating speed 870 rpm or more 710 rpm or more
Lock character-
isticsVo l t a g e 4 V 3 . 5 V
Current 680 A or less 960 A or less
Torque 17 N (1.73 kgf, 12.5 lb) or more 31 N (3.16 kgf, 22.9 lb) or more
GeneratorTy p eRotating-field three-phase type, Voltage regulator built-in type, with load
response control system
ModelEC, EK model: A002TG0391
Other model: A002TB6991
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Rotating direction Clockwise (viewed from pulley side)
Armature connection 3-phase Y-type
Output currentEC, EK model1,500 rpm — 40 A or more
2,500 rpm — 74 A or more
5,000 rpm — 84 A or more
Other model1,500 rpm — 36 A or more
2,500 rpm — 65 A or more
5,000 rpm — 86 A or more
Regulated voltage 14.1 — 14.8 V [20°C (68°F)]

SC(H4SO)-3
STARTING/CHARGING SYSTEM
General Description
B: COMPONENT
1. STARTER
(1) Front bracket (7) Internal gear ASSY (13) Brush holder ASSY
(2) Sleeve bearing (8) Shaft ASSY (14) Sleeve bearing
(3) Lever set (9) Gear ASSY (15) Rear cover
(4) Magnet switch ASSY (10) Packing (16) Rear cover set
(5) Stopper set (11) Yoke ASSY
(6) Over running clutch (12) Armature
SC-00058
(14) (1)
(2)(3)(4)
(10)
(11)(12)
(13)(15)(16) (5)(6)(7)(8) (9)

SC(H4SO)-4
STARTING/CHARGING SYSTEM
General Description
2. GENERATOR
(1) Pulley (5) Rotor (9) Brush
(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal
SC-00144
(1)
(2)
(7)
(8)
(9)
(10)
(11)
(12)
(3)
(4)
(5)(6)

SC(H4SO)-5
STARTING/CHARGING SYSTEM
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn yourself, because each
part in the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

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)
Case.>
3) Remove the intercooler. (Turbo model) 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