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

1. Apply grease to the shaft sliding surfaces of the internal gear assembly.

   Grease: 

   Marutemp #6129 or equivalent 

2. Assemble the shaft to the internal gear assembly.
   Fig 1: Assembling Shaft To Internal Gear Assembly

   Courtesy of SUBARU OF AMERICA, INC.
3. Use the procedures below to assemble the overrunning clutch.
   1. Apply grease to the splines of the shaft.

      Grease: 

      Marutemp #6129 or equivalent 

   2. Attach the overrunning clutch to the shaft.
      Fig 2: Removing Overrunning Clutch From Shaft

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   3. Pass stopper (B) through the shaft assembly, and attach snap ring (A).
      Fig 3: Removing Snap Ring From Shaft

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      NOTE: Use new stoppers and snap rings.
   4. Using a press, pressure fit stopper (B) into snap ring (A).
   Fig 4: Identifying Stopper And Snap Ring

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4. Assemble the overrunning clutch, internal gear assembly, shaft and shift lever as a single unit into the starter housing assembly.
   NOTE: Apply grease to the moving parts of the shift lever.

   Grease: 

   Marutemp #6129 or equivalent 

   Fig 5: Removing Overrunning Clutch

   Courtesy of SUBARU OF AMERICA, INC.
5. Apply grease to the inside of the internal gear assembly and pinion gear, and attach the pinion gear to the internal gear assembly.
   NOTE:

   • Apply grease evenly to the contact surfaces of each gear.
   • Be careful that no debris becomes attached.

   Grease: 

   Molykote® AG650 or equivalent 

   Fig 6: Identifying Pinion Gear From Internal Gear Assembly

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6. Attach rubber seal (A), plate (B), and rubber seal (C).
   Fig 7: Attaching Rubber Seal

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7. Assemble the armature assembly to the yoke assembly.
   Fig 8: Separating Armature Assembly And Yoke Assembly

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8. Attach the armature assembly and yoke assembly to the starter housing assembly together as a single unit.
   NOTE: As shown in the figure, match the protrusion of the yoke assembly to the cut out of the starter housing assembly.
   Fig 9: Matching Protrusion Of Yoke Assembly To Cut Out Of Starter Housing Assembly

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   Fig 10: Identifying Front Starter, Ball And Armature Assembly

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9. Use an appropriate tool (such as correctly sized socket wrenches) and attach the brush holder assembly to the armature assembly.
   NOTE: Be careful not to damage the brushes.
   Fig 11: Identifying Brush Holder Assembly To Armature Assembly

   Courtesy of SUBARU OF AMERICA, INC.
10. Attach the starter cover assembly, and affix to the brush holder assembly with screws (A).

    Tightening torque: 

    1.4 N.m (0.1 kgf-m, 1.0 it-lb) 

11. Tighten through bolts (B) on both sides.

    Tightening torque: 

    6 N.m (0.6 kgf-m, 4.4 ft-lb) 

    Fig 12: Identifying Brush Holder Assembly Screws And Bolts

    Courtesy of SUBARU OF AMERICA, INC.
12. Attach the magnet switch assembly to the starter housing assembly, and tighten the screws.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 13: Locating Magnet Switch Assembly Screws

    Courtesy of SUBARU OF AMERICA, INC.
13. Attach the harness to the M terminal of the magnet switch assembly, and tighten the nuts.

Tightening torque: 

10 N.m (1.0 kgf-m, 7.4 ft-lb) 

Fig 14: Locating Magnet Switch Assembly Nuts

Courtesy of SUBARU OF AMERICA, INC.