Engine 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.

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   3. Install the snap ring to shaft.
      NOTE: Use new snap rings.

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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

      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

   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.

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   3. Pass stopper (B) through the shaft, and attach snap ring (A).
      NOTE: Use new snap rings.

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   4. Using a press, pressure fit stopper (B) into snap ring (A).

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4. Install the armature to the internal gear assembly.

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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.

   Courtesy of SUBARU OF AMERICA, INC.

   Courtesy of SUBARU OF AMERICA, INC.

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.

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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)

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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)

   Courtesy of SUBARU OF AMERICA, INC.

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

Tightening torque: 

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

Courtesy of SUBARU OF AMERICA, INC.