Starting/Charging Systems (H4SO): Starter: Assembly

1. Press-fit the rear bearing into end frame.
   1. Set an appropriate tool (diameter 22 mm) to rear bearing.
   2. Press-fit the rear bearing using a press.
   NOTE:

   • Use a new bearing.
   • Use a flat base.
   • Press-fit the bearing outer ring until it contact to the base bottom.
   Fig 1: Press-Fitting Bearing Outer Ring

   Courtesy of SUBARU OF AMERICA, INC.
2. Press-fit the oilless bearing into shock absorber bearing.
   1. Set an appropriate tool (diameter 20 mm) to oilless bearing.
   2. Press-fit the oilless bearing using a press.
   NOTE:

   • Use a new bearing.
   • Use a flat base.
   • Press-fit the bearing outer ring until it contact to the base bottom.
   Fig 2: Installing Press-Fit Bearing Outer Ring

   Courtesy of SUBARU OF AMERICA, INC.
3. Press-fit the front bearing into front bracket.
   1. Set the front bearing into front bracket.
   2. Set an appropriate tool (2.0-mm thickness plate) to front bracket, and press-fit the front bearing using a press.
   NOTE:

   • Use a new bearing.
   • Measure the protrusion of front bearing after press-fitting, to check if it is within standard value.

   Standard 

   2.0 - 2.4 mm (0.0787 - 0.0945 in) 

   Fig 3: Measuring Protrusion Of Front Bearing

   Courtesy of SUBARU OF AMERICA, INC.
4. Assemble the internal gear and wave washer to shock absorber bearing.
   NOTE: Align with the pawl position of shock absorber bearing to install internal gear.
   Fig 4: Aligning With Pawl Position Of Shock Absorber Bearing

   Courtesy of SUBARU OF AMERICA, INC.
5. Assemble the washer and internal gear to shaft.
   NOTE: Apply grease to the both sides of the shaft spline and washer.

   Grease: 

   DENSO HL50 

   Fig 5: Applying Grease To Both Sides Of Shaft Spline And Washer

   Courtesy of SUBARU OF AMERICA, INC.
6. Assemble the snap ring.
   Fig 6: Assembling Snap Ring

   Courtesy of SUBARU OF AMERICA, INC.
7. Assemble the overrunning clutch to shaft.
   NOTE: Apply grease to the stop ring entire perimeter.

   Grease: 

   DENSO HL50 

   Fig 7: Identifying Stop Ring

   Courtesy of SUBARU OF AMERICA, INC.
8. Install the stopper to shaft as follows:
   1. Insert the snap ring into the shaft groove by lightly tapping it with an appropriate tool (such as a fit socket wrench).
      NOTE: Use a new snap ring.
      Fig 8: Inserting Snap Ring Into Shaft Groove

      Courtesy of SUBARU OF AMERICA, INC.
   2. Press-fit the stopper to snap ring using a press.
   Fig 9: Press-Fit Stopper To Snap Ring Using A Press

   Courtesy of SUBARU OF AMERICA, INC.
9. Install the shaft assembly to front bracket.
   1. Apply grease to the sliding part (A) of lever pin and the pole piece (B) of arm.

      Grease: 

      DENSO HL50 

      Fig 10: Applying Grease To Sliding Part Of Lever Pin And Pole Piece

      Courtesy of SUBARU OF AMERICA, INC.
   2. Insert the lever arm into the position on over running clutch as shown in Fig 11 .
      Fig 11: Inserting Lever Arm Into Position On Over Running Clutch

      Courtesy of SUBARU OF AMERICA, INC.
   3. Align the shaft assembly to the position on front bracket as shown in Fig 12 .
      Fig 12: Aligning Shaft Assembly To Position On Front Bracket

      Courtesy of SUBARU OF AMERICA, INC.
10. Install the rubber seal.
    Fig 13: Installing Rubber Seal

    Courtesy of SUBARU OF AMERICA, INC.
11. Install the planetary gear.
    1. Apply grease to the pin (A) and bushing (B).
       Fig 14: Installing Planetary Gear

       Courtesy of SUBARU OF AMERICA, INC.
    2. Assemble the planetary gear to pin.
    3. Apply grease to the planetary gear clearance (A) and pin upper part (B).
    NOTE:

    • Apply grease so that it contacts each gear.
    • be careful not to allow dirt to get in.

    Grease: 

    DENSO HL50 

    Fig 15: Applying Grease To Planetary Gear Clearance And Pin Upper Part

    Courtesy of SUBARU OF AMERICA, INC.
12. Assemble the brush assembly to end frame.
    NOTE:

    • Be careful not to allow grease to get on brush.
    • Align the rubber seal part with end frame groove.
    Fig 16: Aligning Rubber Seal Part With End Frame Groove

    Courtesy of SUBARU OF AMERICA, INC.

    Tightening torque: 

    1.4 N.m (0.14 kgf-m, 1.03 ft-lb) 

13. Install the armature to end frame.
    NOTE:

    • Apply grease to the rear bearing inner circumference.
    • Be careful not to allow grease to attach to commutator.
    Fig 17: Installing Armature To End Frame
    Courtesy of SUBARU OF AMERICA, INC.

    Grease: 

    DENSO HL50 

14. Set the space ring, then assemble the snap ring.
    Fig 18: Installing New Snap Ring

    Courtesy of SUBARU OF AMERICA, INC.
    NOTE:

    • Use a new bearing.
    • Check the dimension of (A) shown in Fig 19 after assembling snap ring. If it exceeds 5.0 mm (0.20 in), assemble a new snap ring again.
    Fig 19: Checking Dimension Of (A)

    Courtesy of SUBARU OF AMERICA, INC.
15. Install the end frame cover.
    Fig 20: Installing End Frame Cover

    Courtesy of SUBARU OF AMERICA, INC.
16. Assemble the armature plate to yoke.
    NOTE:

    • Align the rotation stopper of armature plate with the drive out part of yoke inner circumference.
    • Be careful of the assembly direction of armature plate.
    Fig 21: Aligning Rotation Stopper Of Armature Plate

    Courtesy of SUBARU OF AMERICA, INC.
17. Assemble the armature to yoke.
    NOTE:

    • Be careful not to allow armature plate to move.
    • It is recommendable to support with cylindrical pipe as shown in Fig 22 .
      Fig 22: Assembling Armature To Yoke

      Courtesy of SUBARU OF AMERICA, INC.
    • Align the positions of cutout of yoke with the rubber part of end frame.
    • Be careful not to damage the magnet.
    Fig 23: Aligning Positions Of Cutout Of Yoke With Rubber Part Of End Frame
    Courtesy of SUBARU OF AMERICA, INC.
18. Assemble the yoke to front bracket.
    NOTE:

    • Apply grease to the end surface of yoke (mating surface with front bracket).
    • Align the drive out position of yoke outer perimeter with the cutout of front bracket.
    Fig 24: Assembling Yoke To Front Bracket

    Courtesy of SUBARU OF AMERICA, INC.
19. Tighten the through bolts on both sides.

    Tightening torque: 

    6 N.m (0.6 kgf-m, 4.4 ft-lb) 

    Fig 25: Tightening Through Bolts On Both Sides

    Courtesy of SUBARU OF AMERICA, INC.
20. Install the rear cover.
    Fig 26: Installing Rear Cover

    Courtesy of SUBARU OF AMERICA, INC.
21. Install the magnet switch assembly to front bracket.
    1. Assemble the plunger hook to lever.
       NOTE: Apply grease to the plunger hook and sleeve inner circumference.

       Grease: 

       DENSO HL50 

       Fig 27: Assembling Plunger Hook To Lever

       Courtesy of SUBARU OF AMERICA, INC.
    2. Assemble the plunger spring and magnet switch to front bracket.
       NOTE: Apply grease to the end surface of magnet switch as shown in Fig 28 .

       Grease: 

       DENSO HL50 

       Fig 28: Applying Grease To End Surface Of Magnet Switch

       Courtesy of SUBARU OF AMERICA, INC.
       Fig 29: Assembling Plunger Spring And Magnet Switch To Front Bracket

       Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten the bolt.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 30: Tightening Bolt

    Courtesy of SUBARU OF AMERICA, INC.
22. Connect the harness to terminal M of magnet switch assembly.

Tightening torque: 

10 N.m (1.0 kgf-m, 7.4 ft-lb) 

Fig 31: Connecting Harness To Terminal M Of Magnet Switch Assembly

Courtesy of SUBARU OF AMERICA, INC.