Starting/Charging Systems (H6DO): Starter: Assembly

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: Pressing Rear Bearing With Press
Courtesy of SUBARU OF AMERICA, INC.
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: Pressing Oilless Bearing Into Shock Absorber Bearing
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Front Bearing, Plate And Front Bracket
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Shock Absorber Bearing, Wave Washer And Internal Gear
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Shock Absorber Bearing, Wave Washer And Internal Gear
Courtesy of SUBARU OF AMERICA, INC.
Assemble the snap ring.

Fig 6: Identifying Snap Ring
Courtesy of SUBARU OF AMERICA, INC.
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.
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 new snap rings.
  
  Fig 8: Identifying Snap Rings
  Courtesy of SUBARU OF AMERICA, INC.
2. Press-fit the stopper to snap ring using a press.
Fig 9: Identifying Snap Rings And Stopper
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Sliding Part Of Lever Pin And Pole Piece Of Arm
  Courtesy of SUBARU OF AMERICA, INC.
2. Insert the lever arm into the position on over running clutch as shown in the figure.
  
  Fig 11: Identifying Lever
  Courtesy of SUBARU OF AMERICA, INC.
3. Align the shaft assembly to the position on front bracket as shown in the figure.
Fig 12: Aligning Shaft Assembly To Position On Front Bracket
Courtesy of SUBARU OF AMERICA, INC.
Install the rubber seal.

Fig 13: Identifying Rubber Seal
Courtesy of SUBARU OF AMERICA, INC.
Install the planetary gear.
1. Apply a grease to the pin (A) and bushing (B).
  
  Fig 14: Identifying Pin And Bushing
  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: Identifying Planetary Gear Clearance And Pin Upper Part
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Brush Assembly To End Frame
Courtesy of SUBARU OF AMERICA, INC.

Tightening torque:

1.4 N.m (0.14 kgf-m, 1.03 ft-lb)

Fig 17: Identifying Rubber Seal Part With End Frame Groove
Courtesy of SUBARU OF AMERICA, INC.
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.
Grease:

DENSO HL50
Set the space ring, then assemble the snap ring.
NOTE:
- Use new snap rings.
- Check the dimension of (A) in the figure after assembling snap ring. If it exceeds 5.0 mm (0.20 in), assemble a new snap ring again.
Fig 18: Identifying Snap Ring
Courtesy of SUBARU OF AMERICA, INC.

Fig 19: Identifying Snap Ring Dimension
Courtesy of SUBARU OF AMERICA, INC.
Install the end frame cover.

Fig 20: Identifying End Frame Cover
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Armature Plate
Courtesy of SUBARU OF AMERICA, INC.
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 the figure.
- Align the positions of cutout portion of yoke with the rubber part of end frame.
- Be careful not to damage the magnet.
Fig 22: Assembling Armature To Yoke
Courtesy of SUBARU OF AMERICA, INC.

Fig 23: Identifying Cutout Portion Of Yoke With Rubber Part
Courtesy of SUBARU OF AMERICA, INC.
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 portion of front bracket.
Fig 24: Locating Drive Out And Cutout
Courtesy of SUBARU OF AMERICA, INC.
Tighten the through bolts on both sides.
Tightening torque:

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

Fig 25: Locating Starter Bolts
Courtesy of SUBARU OF AMERICA, INC.
Install the rear cover.

Fig 26: Locating Rear Cover
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Lever And Plunger
  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 the figure.
  
  Grease:
  
  DENSO HL50
  
  Fig 28: Identifying Magnet Switch
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 29: Identifying Plunger, Plunger Spring And Magnet Switch
  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: Locating Starter Bolts
Courtesy of SUBARU OF AMERICA, INC.
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: Identifying Terminal M
Courtesy of SUBARU OF AMERICA, INC.