On-Vehicle Inspection

NOTE:

The following check is performed with the starter mounted on the vehicle to measure the contact condition of starter magnet switch contact (hereinafter referred to as contact) electrically during engine cranking for check.
If the contact is faulty, its contact resistance is too high and the time required for the contact to switch ON completely is long.

Starter assembly check

Contact resistance measurement method

NOTE:

With the contact resistance measurement method, the resistance when the starter is energized is measured and the resistance increases when the contact is worn and its contact condition degrades.
Since the contact resistance cannot be measured directly, it is calculated from the starter driving current and the voltage between the terminals.

Check the DTC. (Refer to MALFUNCTION SYMPTOMS AND DTC CHECK )
CAUTION: When a diagnostic code is detected, perform troubleshooting by code.
Move the lock lever in the direction of arrow to unlock the three connectors.
Disconnect the three connectors with lock and normal connector from the injector driver.

Fig 1: Removing Connectors From Injector Driver
Courtesy of SUBARU OF AMERICA, INC.
Remove the three bolts and remove the injector driver.

Fig 2: Locating Injector Driver Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).

Fig 3: Locating Intake Manifold Protector Bolts (Bank 1 Side)
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the two connectors of fuel injector.

Fig 4: Locating Fuel Injector Connectors
Courtesy of SUBARU OF AMERICA, INC.
Install the intake manifold protector (bank 1 side) with the two bolts.
Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}
Install the injector driver with the three bolts.
Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}

NOTE: Leave the two upper connectors of injector driver disconnected.

Fig 5: Locating Injector Driver Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the 2 bolts, and remove the intake manifold protector (bank 2 side).

Fig 6: Locating Intake Manifold Protector Bolts (Bank 2 Side)
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the two connectors of fuel injector.

Fig 7: Locating Fuel Injector Connectors
Courtesy of SUBARU OF AMERICA, INC.

Measure the starter driving current while cranking at the position A in the figure five times. Calculate the average and record it.

Fig 8: Measuring Starter Driving Current

Courtesy of SUBARU OF AMERICA, INC.

NOTE:

Since the current generated by the generator may be measured depending on the measurement position, make sure that the current displayed on the electrical tester is within the range shown in the table and the starter driving current is measured properly.

Starter driving current

STARTER DRIVING CURRENT SPECIFICATION

Starter driving current	Starter output
100 to 180 A	1.0 kW (transmission MT) 1.6 kW (transmission AT)

The starter driving current in the table indicates the reference value when the engine is hot.
Perform the cranking for about 2 seconds and then read the value when the current indicated on the circuit tester stabilizes.
Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.

Fig 9: Starter Driving Current Graph

Courtesy of SUBARU OF AMERICA, INC.

Disconnect the battery ground terminal. (Refer to WORKING PRECAUTIONS AND NOTES )
Set the digital tester between the starter terminal M and engine wiring No. 2.

Fig 10: Measuring Between Starter Terminal M And Engine Wiring No. 2
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: Be careful not to short the terminal +B.

NOTE: Attach alligator clips to the leads of electrical tester and secure them on the terminal M and the battery positive terminal side.
Reconnect the battery ground terminal.
Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
Measure the voltage between the starter terminal M and engine wiring No. 2 while cranking 20 times.

Fig 11: Measuring Voltage Between Starter Terminal M And Engine Wiring No. 2
Courtesy of SUBARU OF AMERICA, INC.
CAUTION:
- Be careful not to short the terminal +B.
- If the starter cannot be stopped while the measurement, remove the battery negative terminal to stop the starter, and then check the push button start switch or ignition (starter) switch assembly, starter relay, starter assembly and wiring harness. Replace the faulty parts.
NOTE:
- Since the contact conditions of moving contacts and fixed contacts vary during the operation, it is necessary to measure about 20 times.
- Perform the cranking for about 2 seconds and then read the value when the voltage indicated on the circuit tester stabilizes.
  
  Fig 12: Current Value Graph
  Courtesy of SUBARU OF AMERICA, INC.
- Since the vehicle with the smart entry & start system is equipped with the cranking hold control, cranking is continued for a certain period of time when the engine does not start. To stop cranking, press the push button start switch again.
Calculate the voltage between the starter terminals from the measurement values above.
How to calculate the standard value

Standard value (mV) = 2.5 mΩ (Starter criteria resistance) XAverage value of starter driving current

Calculation example

Average value of starter driving current: 120 A

Starter criteria resistance: 2.5 mΩ

120 X2.5 = 300, and the standard value is 300 mV or less.

Standard value: Measurement voltage (mV) is equal to or less than standard value (mV).

NOTE: Replace the starter contact if the measurement value exceeds the standard value even once among the 20 measurements.

Fig 13: Starter Terminals Voltage Graph
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the battery ground terminal. (Refer to WORKING PRECAUTIONS AND NOTES )
Remove the three bolts and remove the injector driver.

Fig 14: Locating Injector Driver Bolts
Courtesy of SUBARU OF AMERICA, INC.
Remove the 2 bolts, and remove the intake manifold protector (bank 1 side).

Fig 15: Locating Intake Manifold Protector Bolts (Bank 1 Side)
Courtesy of SUBARU OF AMERICA, INC.
Connect the two connectors of fuel injector.

Fig 16: Locating Fuel Injector Connectors
Courtesy of SUBARU OF AMERICA, INC.
Using 2 bolts, install the intake manifold protector (bank 1 side).
Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}
Install the injector driver with the three bolts.
Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}

Fig 17: Locating Injector Driver Bolts
Courtesy of SUBARU OF AMERICA, INC.
Connect the three connectors with lock to the injector driver. Move the lock lever as shown in the figure to lock the three connectors with lock.

Fig 18: Moving Lock Lever
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: For connector with lock, connect the connector securely to lock it.
Connect the two connectors of fuel injector.

Fig 19: Locating Fuel Injector Connectors
Courtesy of SUBARU OF AMERICA, INC.
Using 2 bolts, install the intake manifold protector (bank 2 side). Standard value: T=19N.m {194kgf.cm} {14.0ft.lbf}

Fig 20: Locating Intake Manifold Protector Bolts (Bank 2 Side)
Courtesy of SUBARU OF AMERICA, INC.
Reconnect the battery ground terminal.
Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
Make sure that there is no influence on the engine startability and after the engine is started.