Starting System & Charging System (H4SO): Starter: Assembly

1. Set an appropriate tool (ø22 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: Installing Rear Bearing

     Courtesy of SUBARU OF AMERICA, INC.

1. Set an appropriate tool (ø20 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: Installing Oilless Bearing

     Courtesy of SUBARU OF AMERICA, INC.

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: Pressing Front Bearing Into Front Bracket

   Courtesy of SUBARU OF AMERICA, INC.

Grease: 

DENSO HL50 

Fig 5: Assembling Washer And Internal Gear To Shaft

Courtesy of SUBARU OF AMERICA, INC.

Grease: 

DENSO HL50 

Fig 7: Identifying Stop Ring

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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 Ring And Stopper

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2. Press-fit the stopper to snap ring using a press.
   Fig 9: Pressing Stopper To Snap Ring

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1. Apply grease to the sliding part (A) of lever pin and the pole piece (B) of arm.

   Grease: 

   DENSO HL50 

   Fig 10: Identifying Grease Applying Area

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2. Insert the lever arm into the position on over running clutch as shown in the figure.
   Fig 11: Inserting Lever Arm

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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

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1. Apply a grease to the pin (A) and bushing (B).
   Fig 14: Identifying Pin And Bushing

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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 Grease Applying To Planetary Gear

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Tightening torque: 

1.4 N.m (0.14 kgf-m, 1.03 ft-lb) 

Fig 17: Locating Screws

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Grease: 

DENSO HL50 

Tightening torque: 

6 N.m (0.6 kgf-m, 4.4 ft-lb) 

Fig 25: Locating Through Bolts

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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 Hook

   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 End Surface Of Magnet Switch

   Courtesy of SUBARU OF AMERICA, INC.
   Fig 29: Identifying Plunger, Plunger Spring And Magnet Switch

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3. Tighten the bolt.

   Tightening torque: 

   7.5N.m (0.8kgf-m, 5.5 ft-lb) 

   Fig 30: Locating Switch Assembly Bolts

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Tightening torque: 

10N.m(1.0kgf-m, 7.4 ft-lb) 

Fig 31: Identifying Terminal M Of Magnet Switch Assembly

Courtesy of SUBARU OF AMERICA, INC.