Section 4 (Starting System & Charging System (STI)): Starter: Assembly

WARNING: This page is about a different variant/trim than selected.

Use the following procedures to install the shaft.
1. Apply grease to the shaft sliding surfaces of the internal gear assembly.
  Grease:
  
  DENSO HL50
2. Assemble the shaft to the internal gear assembly.
  
  Fig 1: Identifying Shaft Of Internal Gear Assembly
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the snap ring to shaft.
  NOTE: Use new snap rings.
  
  Fig 2: Installing Snap Ring To Shaft
  Courtesy of SUBARU OF AMERICA, INC.
4. Apply grease to the pinion gear attachment area.
  Grease:
  
  DENSO HL50
5. Attach the pinion gear to the pin.
6. Apply grease to the pinion gear, internal gear assembly, and on top of the shaft pin.
  NOTE:
  - Apply grease so that it contacts each gear.
  - Be careful not to allow dirt to get in.
  Grease:
  
  DENSO HL50
  
  Fig 3: Identifying Starter Plate And Pinion Gear
  Courtesy of SUBARU OF AMERICA, INC.
7. Install the starter plate.
Assemble the overrunning clutch and shift lever (B) to the starter housing (A) as a unit.
NOTE: Apply grease to the contact portion of the shift lever.

Grease:

DENSO HL50

Fig 4: Identifying Starter Housing Assembly And Shift Lever
Courtesy of SUBARU OF AMERICA, INC.
Assemble the overrunning clutch as follows:
1. Apply grease to the spline portion of the shaft.
  Grease:
  
  DENSO HL50
2. Install the overrunning clutch to shaft.
  
  Fig 5: Installing Overrunning Clutch To Shaft
  Courtesy of SUBARU OF AMERICA, INC.
3. Pass stopper (B) through the shaft, and attach snap ring (A).
  NOTE: Use new snap rings.
  
  Fig 6: Attaching Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
4. Using a press, pressure fit stopper (B) into snap ring (A).
  
  Fig 7: Pressing Pressure Fit Stopper Into Snap Ring
  Courtesy of SUBARU OF AMERICA, INC.
Install the armature to the internal gear assembly.

Fig 8: Identifying Armature Of Internal Gear Assembly
Courtesy of SUBARU OF AMERICA, INC.
Attach the two brushes wired to the yoke assembly to the brush holder assembly.
NOTE: As shown in the figure, use a flat tip screwdriver, etc. to hold the brush spring and insert the brush while being careful not to damage the brush.

Fig 9: Attaching Brushes Wired To Yoke Assembly
Courtesy of SUBARU OF AMERICA, INC.

Fig 10: Identifying Yoke Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install the yoke assembly and brush holder assembly as a single unit to the armature.
NOTE: Spread the brush with your fingers, being careful not to damage the brush.

Fig 11: Identifying Yoke Assembly And Brush Holder Assembly
Courtesy of SUBARU OF AMERICA, INC.
Install starter cover assembly to the brush holder assembly with screws (B).
Tightening torque:

1.4 N.m (0.1 kgf-m, 1.0 ft-lb)
Tighten the through bolts (A) on both sides.
Tightening torque:

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

Fig 12: Identifying Starter Cover Assembly Bolts And Screws
Courtesy of SUBARU OF AMERICA, INC.
Attach the magnet switch assembly to the starter housing assembly.
Tightening torque:

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

Fig 13: Locating Magnet Switch Assembly Nuts
Courtesy of SUBARU OF AMERICA, INC.
Connect terminal M (A) to magnet switch assembly.
Tightening torque:

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

Fig 14: Identifying Terminal M Of Magnet Switch Assembly
Courtesy of SUBARU OF AMERICA, INC.