Starter Assembly (Fa20): Reassembly

Install Starter Clutch Sub-Assembly (For Manual Transmission)
1. Apply grease to the shaft as shown in the illustration.
  
  Fig 1: Identifying Grease Application Area On Shaft
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the internal gear to the shaft.
  
  Fig 2: Installing Internal Gear To Shaft
  Courtesy of SUBARU OF AMERICA, INC.
3. Apply grease to the shaft as shown in the illustration.
  
  Fig 3: Identifying Grease Application Area On Shaft
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the over running clutch to the shaft.
  
  Fig 4: Installing Running Clutch To Shaft
  Courtesy of SUBARU OF AMERICA, INC.
5. Install the stopper to the shaft.
  Using snap ring pliers, install the snap ring.
  
  Fig 5: Installing Stopper To Shaft Using Snap Ring Pliers
  Courtesy of SUBARU OF AMERICA, INC.
6. Using a press, press the snap ring into the stopper.
  
  Fig 6: Pressing Snap Ring Into Stopper Using Press
  Courtesy of SUBARU OF AMERICA, INC.
7. Install the starter clutch sub-assembly together with the drive lever set pin to the starter drive housing assembly.
  
  Fig 7: Installing Starter Clutch Sub-Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Planetary Gear (For Manual Transmission)
1. Apply high-temperature grease to the planetary gears and pins of the planetary shaft.
2. Install the 3 starter planetary gears.
  
  Fig 8: Locating Starter Planetary Gear Grease Application Areas (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Planetary Gear (For Automatic Transmission)
1. Apply high-temperature grease to the planetary gears and pins of the planetary shaft.
2. Install the 3 starter planetary gears.
  
  Fig 9: Locating Starter Planetary Gear Grease Application Areas (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Housing Rubber (For Manual Transmission)
1. Install the starter housing rubber, seal rubber and plate to the starter drive housing assembly.
  
  Fig 10: Installing Starter Housing Rubber, Plate, Seal Rubber (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Rubber Seal (For Automatic Transmission)
1. Install the rubber seal to the starter drive housing assembly.
  
  Fig 11: Installing Starter Drive Housing Assembly Rubber Seal (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Armature Assembly (For Automatic Transmission)
1. Install the starter armature assembly to the starter yoke assembly.
  
  Fig 12: Installing Starter Armature Assembly To Yoke Assembly (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Brush Holder Assembly (For Automatic Transmission)
1. Install the 4 brushes and 4 brush springs.
  
  Fig 13: Installing Brushes And Brush Springs (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the starter brush holder assembly to the starter armature assembly. Push the 4 brushes.
  
  Fig 14: Installing Starter Brush Holder Assembly To Starter Armature Assembly (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
3. Insert the grommet between the positive (+) motor read wire and the negative (-) brush holder plate.
  
  Fig 15: Installing Grommet Between Positive Motor Read Wire And Negative Brush Holder Plate (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Cover (For Automatic Transmission)
1. Install the dust starter protector to the starter yoke assembly.
2. Align the starter brush holder assembly read wire rubber with the groove of the starter cover.
  
  Fig 16: Installing Dust Starter Protector To Starter Yoke Assembly (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the starter cover to the starter brush holder assembly with 2 screws.
  Standard value: T=1.5N.m {15kgf.cm} {1.1ft.lbf}
  
  Fig 17: Locating Starter Brush Holder Assembly Screws (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Armature Plate (For Automatic Transmission)
1. Align the claw of the starter yoke assembly with the groove the starter armature plate.
2. Install the starter armature plate to the starter yoke assembly.
  
  Fig 18: Locating Starter Yoke Assembly Claw (For Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Armature Assembly (For Manual Transmission)
1. Install the starter armature assembly to the starter yoke assembly.
  
  Fig 19: Installing Starter Armature Assembly And Yoke Assembly (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Yoke Assembly (For Manual Transmission)
1. Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly.
  
  Fig 20: Locating Starter Yoke Assembly Claw (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
2. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.
  
  Fig 21: Installing Starter Yoke Assembly (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Yoke Assembly (For Automatic Transmission)
1. Align the claw of the starter yoke assembly with the groove inside the starter drive housing assembly. Install the starter yoke assembly together with the starter armature assembly to the starter drive housing assembly.
  
  Fig 22: Installing Starter Yoke Assembly (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
2. Using a "TORX" socket wrench T25, install the 2 through bolts.
  Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
  
  Fig 23: Installing Starter Yoke Assembly Bolts (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Brush Holder Assembly (For Manual Transmission)
1. Install a socket to the starter brush holder assembly.
2. Install the starter brush holder assembly to the starter armature assembly.
  
  Fig 24: Installing Starter Brush Holder Assembly (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Starter Cover (For Manual Transmission)
1. Install the starter cover with 2 screws and 2 bolts.
  Torque: Bolt 6.0 N.m {61 kgf.cm} {4.4ft.lbf}
  
  Screw 1.4 N.m {14 kgf.cm} {1.0ft.lbf}
  
  Fig 25: Locating Starter Cover Screws And Bolts (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Magnet Starter Switch Assembly (For Manual Transmission)
1. Install the magnet starter switch assembly with the 2 screws.
  Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
  
  Fig 26: Locating Magnet Starter Switch Assembly Screws (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
2. Connect the lead wire to terminal C with the nut.
  Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
  
  Fig 27: Locating Lead Wire And Nut (Manual Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
Install Magnet Starter Switch Assembly (For Automatic Transmission)
1. Apply grease to the plunger and hook as shown in the illustration.
  
  Fig 28: Plunger And Hook Grease Application Area (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
2. Hook the plunger and hook of the magnet starter switch assembly to the lever of the starter drive housing assembly.
  
  Fig 29: Installing Plunger And Hook To Lever (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the magnet starter switch assembly with the 2 screws.
  Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
  
  Fig 30: Locating Magnet Starter Switch Assembly Nuts (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.
4. Connect the lead wire to terminal C with the nut.
  Standard value: T=10N.m {102kgf.cm} {7.4ft.lbf}
  
  Fig 31: Connecting Lead Wire To Terminal C (Automatic Transmission)
  Courtesy of SUBARU OF AMERICA, INC.