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At Model

  1. Apply grease to the inside of the internal gear, pinion stopper washer and pinion gear, and attach the pinion stopper washer and pinion gear to the internal gear.
    NOTE: Apply grease evenly to the contact surfaces of each gear.

    Preparation items: 

    Grease: Denso HL50 or equivalent

    G16524653Courtesy of SUBARU OF AMERICA, INC.
  2. Install the seal rubber to the starter drive housing assembly.
    G16524638Courtesy of SUBARU OF AMERICA, INC.
  3. Set the armature assembly to the yoke assembly.
    G16524636Courtesy of SUBARU OF AMERICA, INC.
  4. Install the brush holder assembly.
    1. Set 4 brushes in the brush holder.
      G16524656Courtesy of SUBARU OF AMERICA, INC.
    2. Install the brush holder to the yoke assembly and install the spring to the bushing on each brush.
      G16524657Courtesy of SUBARU OF AMERICA, INC.
    3. Insert the grommet (C) between the lead wire (A) of the brush and the brush holder (B).
    G16524658Courtesy of SUBARU OF AMERICA, INC.
  5. Set the drain duct (A) to the yoke assembly and install the starter cover.

    Tightening torque: 

    1.5 N.m (0.2 kgf-m, 1.1 ft-lb)

    G16524634Courtesy of SUBARU OF AMERICA, INC.
  6. Install the plate to the yoke assembly.
    G16524660Courtesy of SUBARU OF AMERICA, INC.
  7. Install the yoke assembly and starter cover to the starter drive housing assembly as a single unit.
    NOTE: Match the protrusion of the yoke assembly to the cutout of the starter drive housing assembly.
    G16524661Courtesy of SUBARU OF AMERICA, INC.
  8. Using TORX® T25, install the through bolts.

    Tightening torque: 

    6 N.m (0.6 kgf-m, 4.4 ft-lb)

    G16524632Courtesy of SUBARU OF AMERICA, INC.
  9. Install the magnet switch assembly.
    1. Apply grease to the shift lever hook and the magnet switch plunger.

      Preparation items: 

      Grease: Denso HL50 or equivalent

      G16524663Courtesy of SUBARU OF AMERICA, INC.
    2. Set the magnet switch plunger (B) to the shift lever hook (A).
      G16524664Courtesy of SUBARU OF AMERICA, INC.
    3. Tighten the nuts securing the magnet switch assembly.

      Tightening torque: 

      7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

      G16524631Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the cable to the terminal M.

    Tightening torque: 

    10 N.m (1.0 kgf-m, 7.4 ft-lb)

    G16524630Courtesy of SUBARU OF AMERICA, INC.
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