Subaru Outback manuals

Subaru Outback: Starter

A: REMOVAL

1) Disconnect the ground cable from battery.

Subaru Outback. Starting/Charging Systems

2) Remove the cover (A) and clip (B) from air intake boot assembly. (2.5 L non-turbo model)

Subaru Outback. Starting/Charging Systems

3) Loosen the clamp (A) which connects the air intake boot assembly and air cleaner case. (2.5 L non-turbo model)

4) Loosen the clamp (B) which connects the air intake boot assembly and throttle body. (2.5 L non-turbo model)

Subaru Outback. Starting/Charging Systems

5) Remove the air intake boot from the throttle body, and move it to the left side wheel apron. (2.5 L non-turbo model)

Subaru Outback. Starting/Charging Systems

6) Loosen the clamp (A) which connects the air intake boot assembly. (3.6 L model)

7) Loosen the bolt (B) which secures the air intake boot assembly to the collector cover bracket. (3.6 L model)

Subaru Outback. Starting/Charging Systems

8) Remove the air intake boot assembly, and move it to the left side wheel apron. (3.6 L model)

Subaru Outback. Starting/Charging Systems

9) Remove the intercooler. (turbo model) <Ref. to IN(H4DOTC)-17, REMOVAL, Intercooler.>

10) Disconnect the connector (B) and terminal (A) from starter.

Subaru Outback. Starting/Charging Systems

11) Remove the starter from transmission.

NOTE: For the MT model, a bolt is used in place (A).

Subaru Outback. Starting/Charging Systems

B: INSTALLATION

Install in the reverse order of removal.

NOTE: For the MT model, a bolt is used in place (A).

Tightening torque: 50 N*m (5.1 kgf-m, 36.9 ft-lb)

Subaru Outback. Starting/Charging Systems

Tightening torque: 10 N*m (1.0 kgf-m, 7.4 ft-lb)

Subaru Outback. Starting/Charging Systems

NOTE: Align the clamp hole with the protrusion of the air intake boot assembly.

Subaru Outback. Starting/Charging Systems

Tightening torque:

Clamp (A), (B)
3 N*m (0.3 kgf-m, 2.2 ft-lb)

Subaru Outback. Starting/Charging Systems

Tightening torque:

Clamp (A)
3 N*m (0.3 kgf-m, 2.2 ft-lb)

Bolt (B)
6.5 N*m (0.7 kgf-m, 4.8 ft-lb)

Subaru Outback. Starting/Charging Systems

C: DISASSEMBLY

1) Remove the nut which holds terminal M (A) of the magnet switch assembly, then disconnect the harness from the terminal.

Subaru Outback. Starting/Charging Systems

2) Remove the nuts fastening the magnet switch assembly to the starter housing, then remove the magnet switch assembly.

Subaru Outback. Starting/Charging Systems

3) Remove the starter seal.

Subaru Outback. Starting/Charging Systems

4) Remove the through bolts on both sides, and remove the starter housing.

Subaru Outback. Starting/Charging Systems

5) Remove the shift lever.

Subaru Outback. Starting/Charging Systems

6) Remove the overrunning clutch assembly from the yoke.

Subaru Outback. Starting/Charging Systems

7) Remove the starter plate.

Subaru Outback. Starting/Charging Systems

8) Remove the planetary gear (A) and washer (B) from internal gear.

Subaru Outback. Starting/Charging Systems

9) Remove the screws, and remove the starter cover from the brush holder assembly.

NOTE: Separate the starter cover by pressing the brush holder assembly using the screws so that the assembly stays onto the armature side.

Subaru Outback. Starting/Charging Systems

10) Remove the brush holder assembly from the armature.

NOTE: Spread the brush with your fingers, being careful not to damage the brush.

Subaru Outback. Starting/Charging Systems

11) Remove the armature from the yoke.

Subaru Outback. Starting/Charging Systems

D: ASSEMBLY

1) Install the armature to the yoke.

Subaru Outback. Starting/Charging Systems

2) Install the brush holder assembly to the armature.

NOTE: Spread the brush with your fingers, being careful not to damage the brush.

Subaru Outback. Starting/Charging Systems

3) Install the starter cover, and secure it to the brush holder assembly with the screws.

Subaru Outback. Starting/Charging Systems

4) Assemble the planetary gear (A) and washer (B) to the internal gear.

  1. Apply grease to the planetary gear installation position.

Grease: DENSO HL50

  1. Install the planetary gear to the pin.
  2. Apply grease to the planetary gear, internal gear, washer, and upper part of the pin.

NOTE:

Grease: DENSO HL50

Subaru Outback. Starting/Charging Systems

  1. Install the starter plate.

Subaru Outback. Starting/Charging Systems

5) Assemble the overrunning clutch assembly to the yoke.

Subaru Outback. Starting/Charging Systems

6) Install the shift lever.

NOTE: Apply grease to the contact portion of the shift lever.

Grease: DENSO HL50

Subaru Outback. Starting/Charging Systems

7) Install the starter housing, and tighten through bolts on both sides.

Tightening torque: 6 N*m (0.6 kgf-m, 4.4 ft-lb)

Subaru Outback. Starting/Charging Systems

8) Install the starter seal.

Subaru Outback. Starting/Charging Systems

9) Install the magnet switch assembly to the starter housing, and tighten the nuts.

NOTE: Apply grease to the shift lever installation position.

Grease: DENSO HL50

Tightening torque: 7.5 N*m (0.8 kgf-m, 5.5 ft-lb)

Subaru Outback. Starting/Charging Systems

10) Install the harness to the terminal M (A) of the magnet switch assembly, and tighten the nut.

Tightening torque: 10 N*m (1.0 kgf-m, 7.4 ft-lb)

Subaru Outback. Starting/Charging Systems

E: INSPECTION

1. SWITCH ASSEMBLY

Using a circuit tester (set to "ohm"), check that there is continuity between terminals S and M, and between terminal S and ground.

Also check to be sure there is no continuity between terminals M and B.

Terminal/Resistance:

S - M/1 Ω or less
S - Ground/1 Ω or less
M - B/1 MΩ or more

Subaru Outback. Starting/Charging Systems

  1. Terminal S
  2. Terminal M
  3. Terminal B

2. SWITCH ASSEMBLY OPERATION

NOTE: Perform each test in a short period of time (3 - 5 sec).

1) Suction test

Check that the pinion gear comes flying out when the harness is disconnected from terminal M and connected as shown in the figure.

Subaru Outback. Starting/Charging Systems

  1. Terminal S
  2. Terminal M

2) Holding test

Check that the pinion gear remains flying out after the cable is disconnected from terminal M.

Subaru Outback. Starting/Charging Systems

  1. Terminal S
  2. Terminal M

3) Returning test

With terminal S connected to the positive terminal, and terminal M and starter body connected to the battery ground terminal to suction the main contact point, check that the pinion gear returns to its original position when terminal S is disconnected.

Subaru Outback. Starting/Charging Systems

  1. Terminal S
  2. Terminal M

3. 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.

Subaru Outback. Starting/Charging Systems

  1. Variable resistance
  2. Magnetic switch
  3. Starter body

1) No-load test

Adjust the variable resistance with the switch on until the voltage is 11 V, and read the value displayed on the ammeter to measure rotating speed.

Compare these values with the standard.

No-load test (standard):

Voltage/Current
Max. 11 V/90 A or less

Rotating speed

2.5 L model
1,900 rpm or more

3.6 L model
1,550 rpm or more

2) Load test

Apply the specified braking torque to starter. The condition is normal if the current draw and rotating speed are within standard.

Load test (standard):

Voltage/Load

2.5 L model
8 V/11.1 N*m (1.1 kgf-m, 8.2 ft-lb) or more

3.6 L model
8 V/12.8 N*m (1.3 kgf-m, 9.4 ft-lb) or more

Current/Rotating speed

2.5 L model
370 A/910 rpm or more

3.6 L model
370 A/800 rpm or more

3) Lock test

With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to standard voltage.

Lock test (standard):

Voltage/Current
3 V/750 A or less

Torque

2.5 L model
15.5 N*m (1.6 kgf-m, 11.4 ft-lb) or more

3.6 L model
19.0 N*m (1.9 kgf-m, 14.0 ft-lb) or more

4. OTHER INSPECTIONS

Check that the starter does not have deformation, cracks and any other damage.

READ NEXT:

 Generator

A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the V-belts. <Ref. to ME(H4SO)-43, VBELT, REMOVAL, V-belt.> <Ref. to ME(H4DOTC)-42, V-BELT, REMOVAL, V-belt.> <Ref. t

 Battery

A: REMOVAL 1) After disconnecting the battery ground terminal, remove the terminal cover, then disconnect the positive terminal. 2) Remove the battery cable holder from the battery rod. 3) Remove fl

 Engine (Diagnostics)

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 Hazard warning flasher

The hazard warning flasher is used to warn other drivers when you have to park your vehicle under emergency conditions. The hazard warning flasher works with the ignition switch in any position. To turn on the hazard warning flasher, press the hazard warning button on the instrument panel.

 Differential Gear Oil

A: INSPECTION 1) Remove the filler plug, and then check the gear oil. Replace the gear oil if it is contaminated, deteriorated or cloudy. <Ref. to DI-23, REPLACEMENT, Differential Gear Oil.> 2) Check that the gear oil level is within -5 mm (- 0.2 in) from the bottom of the filler plug hole. I

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