Section 1 (Starting System & Charging System (2.5L)): Starter: Assembly

1. 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: Assembling Shaft To 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

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   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: Grease Application Area Of Internal Gear Assembly

      Courtesy of SUBARU OF AMERICA, INC.
   7. Install the starter plate.
2. 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: Locating Starter Housing Assembly And Shift Lever

   Courtesy of SUBARU OF AMERICA, INC.
3. 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 To Shaft

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   4. Using a press, pressure fit stopper (B) into snap ring (A).
      Fig 7: Pressing Pressure Fit Stopper Into Snap Ring Using Press

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4. Install the armature to the internal gear assembly.
   Fig 8: Locating Armature Of Starter

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5. 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: Holding Brush Spring Using Flat Tip Screwdriver

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   Fig 10: Brush Of Starter

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6. 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: Brush Holder Assembly Of Starter

   Courtesy of SUBARU OF AMERICA, INC.
7. 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) 

8. Tighten the through bolts (A) on both sides.

   Tightening torque: 

   6 N.m (0.6 kgf-m, 4.4 ft-lb) 

   Fig 12: Locating Starter Cover Assembly Bolts

   Courtesy of SUBARU OF AMERICA, INC.
9. 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 Bolts

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10. Connect terminal M (A) to magnet switch assembly.

Fig 14: Locating Magnet Switch Assembly Terminal

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Tightening torque: 

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