2001 СУБАРУ ФОРЕСТЕР. Руководство по обслуживанию

STARTER

Starting/Charging Systems

				- AT vehicles
2. Starter	S179012


A: REMOVAL		S179012A18
1) Disconnect battery ground cable.

				5) Disconnect connector and terminal from starter.

2) Remove air cleaner case. (Non-Turbo Model)

			(A) Terminal (B) Connector 6) Remove starter from transmission.

3) Remove intercooler. (Turbo Model) <Ref. to IN(DOHC TURBO) -10, REMOVAL, Intercooler.> 4) Remove air cleaner case stay. (Non-Turbo Model) - MT vehicles

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STARTER

Starting/Charging Systems

			3) Remove both through-bolts and brush holder screws, and detach rear bracket and brush holder.
B: INSTALLATION	S179012A11
Install in the reverse order of removal. *Tightening torque:* *50 Nm (5.1 kgf-m, 37 ft-lb)*


				(A) Brush holder (B) Rear bracket 4) Remove armature and yoke. Ball used as a bearing will then be removed from the end of armaВture. CAUTION: Be sure to mark an alignment mark on yoke and front bracket before removing yoke.
C: DISASSEMBLY	S179012A06
1. STARTER ASSEMBLY		S179012A0601
1) Loosen nut which holds terminal M of switch assembly, and disconnect connector. 2) Remove bolts which hold switch assembly, and remove switch assembly, plunger and plunger spring from starter as a unit. CAUTION: Be careful because pinion gap adjustment washer may sometimes be used on the mountВing surface of switch assembly.


				(A) Front bracket (B) Yoke (C) Ball (D) Awature

(A) Switch ASSY (B) Plunger

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STARTER

Starting/Charging Systems

5) Remove packing A, three planetary gears, packing B and plate.

	(A) Stopper (B) Tool (C) Ring (D) Shaft 2. BRUSH HOLDER		S179012A0602
(A) Packing A (B) Planetary gear (C) Plate (D) Packing B 6) Remove shaft assembly and overrunning clutch as a unit. CAUTION: Record the direction of lever before removing.			S179012A0602
	Slightly open the metal fitting holding the insulating plate to the brush holder. Remove the insulating plate. NOTE: The brush and spring can be easily removed from the brush holder at this time.


(A) Shaft ASSY (B) Overrunning clutch (C) Lever 7) Remove overrunning clutch from shaft assemВbly as follows: (1) Remove stopper from ring by lightly tapping a fit tool placed on stopper. (2) Remove ring, stopper and clutch from shaft.
	(A) Brush holder (B) Insulating plate (C) Metal fitting D: ASSEMBLY	S179012A02
	Assembly is in the reverse order of disassembly procedures. Do the following: 1) Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been overlooked. 2) Apply grease to the following parts during assembly. Front and rear bracket sleeve bearing Armature shaft gear Outer periphery of plunger Mating surface of plunger and lever Gear shaft splines Mating surface of lever and clutch Ball at the armature shaft end Internal and planetary gears

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STARTER

Starting/Charging Systems

3) After assembling parts correctly, make sure starter operates properly.				4) Armature short-circuit test Check armature for short-circuit by placing it on growler tester. Hold a hacksaw blade against armature core while slowly rotating armature. A short-circuited armature will cause the blade to vibrate and to be attracted to core. If the hacksaw blade is attracted or vibrates, the armature, which is short-circuited, must be replaced or repaired.
E: INSPECTION		S179012A10
1. ARMATURE	S179012A1001
1) Check commutator for any sign of burns of rough surfaces or stepped wear. If wear is of a minor nature, correct it by using sand paper. 2) Run-out test Check the commutator run-out and replace if it exceeds the limit. *Commutator run-out: Standard* *0.05 mm (0.0020 in) Service limit* *Less than 0.10 mm (0.0039 in)*


				(A) Iron sheet (B) Grower 5) Armature ground test Using circuit tester, touch one probe to the comВmutator segment and the other to shaft. There should be no continuity. If there is a continuity, armature is grounded. Replace armature if it is grounded.

(A) V-block 3) Depth of segment mold Check the depth of segment mold. *Depth of segment mold: 0.5 mm (0.020 in)*

			2. YOKE S179012A1002 Make sure pole is set in position. 3. OVERRUNNING CLUTCH		S179012A1003
			Inspect teeth of pinion for wear and damage. Replace if it is damaged. Rotate pinion in direction of rotation (counterclockwise). It should rotate smoothly. But in opposite direction, it should be locked. CAUTION: Do not clean overrunning clutch with oil to preВvent grease from flowing out.
(A) Depth of mold (B) Segment (C) Mold

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STARTER

Starting/Charging Systems

4. BRUSH AND BRUSH HOLDER		S179012A1004	Terminal / Specified resistance: S - M/ Less than 1 Q S - Ground / Less than 1 D. M-B/More than 1 MQ
1) Brush length Measure the brush length and replace if it exceeds the service limit. Replace if abnormal wear or cracks are noticed. Brush length: Standard 12.3 mm (0.484 in) Service limit 7.0 mm (0.276 in)


			6. SWITCH ASSEMBLY OPERATION
			S179012A1006
			1) Connect terminal S of switch assembly to posiВtive terminal of battery with a lead wire, and starter body to ground terminal of battery. Pinion should be forced endwise on shaft. CAUTION: With pinion forced endwise on shaft, starter motor can sometimes rotate because current flows, through pull-in coil, to motor. This is not a problem. 2) Disconnect connector from terminal M, and connect positive terminal of battery and terminal M using a lead wire and ground terminal to starter body. In this test set up, pinion should return to its origiВnal position even when it is pulled out with a screwВdriver.
(A) Service limit line (B) Brush 2) Brush movement Be sure brush moves smoothly inside brush holder. 3) Brush spring force Measure brush spring force with a spring scale. If it is less than the service limit, replace brush holder. Brush spring force: Standard 21.6 N (2.2 kgf, 4.9 lb) (when new) Service limit 5.9 N (0.6 kgf, 1.3 lb)

5. SWITCH ASSEMBLY	S179012A1005

Be sure there is continuity between terminals S and M, and between terminal S and ground. Use a circuit tester (set in "ohm"). Also check to be sure there is no continuity between terminal M and B.

(A) Terminal S (B) Terminal M

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STARTER

Starting/Charging Systems

7. PINION GAP S1790₁2A1007 1) Measure pinion gap while the pinion is pulled out as shown in the figure. Pinion gap: 0.5-2.0 mm (0.020 - 0.079 in)

		(A) Variable resistance (B) Magnetic switch (C) Starter body 1) No-load test With switch on, adjust the variable resistance to obtain 11 V, take the ammeter reading and meaВsure the starter speed. Compare these values with the specifications. No-load test (Standard): Voltage / Current 11 V/90 A max. Rotating speed MT vehicles 2,800 rpm or more AT vehicles 2,400 rpm or more 2) Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within specifications. Load test (Standard): Voltage / Load MT vehicles 7.5 V/8.6 Nm (0.88 kgf-m, 6.4 ft-lb) AT vehicles 7.7 V/16.0 Nm (1.63 kgf-m, 11.8 ft-lb) Current / Speed MT vehicles 300 A/920 rpm or more AT vehicles 400 A/740 rpm or more
(A) Pinion (B) Gap (C) Stopper If motor is running with the pinion forced endwise on the shaft, disconnect connector from terminal M of switch assembly and connect terminal M to ground terminal (-) of battery with a lead wire. Next, gently push pinion back with your fingertips and measure pinion gap. 2) If pinion gap is outside specified range, remove or add number of adjustment washers used on the mounting surface of switch assembly until correct pinion gap is obtained.
8. PERFORMANCE TEST	S179012A1008
The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test. For these performance tests, use the circuit shown in figure.

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	STARTER Starting/Charging Systems

	3) Lock test With starter stalled, or not rotating, measure the torque developed and current draw when the voltВage is adjusted to the specified voltage. *Lock test (Standard):* *Voltage / Current MT vehicles* *4 V/650 A or less AT vehicles* *3.5 V/940 A or less* *Torque MT vehicles* *14.7 Nm (1.50 kgf-m, 10.8 ft-lb) or more AT vehicles* *28.9 Nm (2.95 kgf-m, 21.3 ft-lb) or more*

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