Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual — part 115

SC(STI)-16

Starter

STARTING/CHARGING SYSTEMS

3) Assemble the overrunning clutch as follows:

(1) Apply grease to the spline portion of the

shaft.

Grease:

Multemp #6129 or equivalent

(2) Install the overrunning clutch to shaft.

(3) Pass stopper (B) through the shaft assem-

bly, and attach snap ring (A).

NOTE:

Use new stoppers and snap rings.

(4) Using a press, pressure fit stopper (B) into

snap ring (A).

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:

Multemp #6129 or equivalent

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

6) Install seal rubber (A), plate (B), and seal rubber

(C).

SC-02233

SC-02134

(A)

(B)

SC-00068

(A)

(B)

SC-02235

SC-02229

(A)

SC-02230

(B)

(C)

SC(STI)-17

Starter

STARTING/CHARGING SYSTEMS

7) Assemble the armature assembly to the yoke

assembly.

8) Attach the armature assembly and yoke assem-

bly 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.

9) Use an appropriate tool (such as correctly sized

socket wrenches) and attach the brush holder as-

sembly to the armature assembly.
NOTE:

Be careful not to damage the brushes.

10) Secure starter cover assembly to the brush

holder assembly with screws (A).
Tightening torque:

1.4 N·m (0.1 kgf-m, 1.0 ft-lb)

11) Install through bolts (B) on both sides.
Tightening torque:

6 N·m (0.6 kgf-m, 4.4 ft-lb)

12) Attach the magnet switch assembly to the start-

er housing assembly.
Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

SC-02228

SC-02236

SC-02227

SC-02237

SC-02225

(A)

(B)

SC-02224

SC(STI)-18

Starter

STARTING/CHARGING SYSTEMS

13) Attach the cable to the terminal M of the mag-

net switch assembly, and secure with nuts.
Tightening torque:

10 N·m (1.0 kgf-m, 7.4 ft-lb)

E: INSPECTION

1. ARMATURE

1) Check the commutator for signs of seizure or

stepped wear caused by roughness of the surface.

If there is light wear, use sandpaper to repair.

2) Check for runout on the commutator. If exces-

sive, replace the armature.
Commutator runout:

Standard

0.05 mm (0.0020 in)

Limit

0.10 mm (0.0039 in)

3) Check the depth of the segment mold. If it is not

within the standard, replace the armature.
Depth of segment mold:

Standard

0.5 mm (0.020 in)

4) Place the armature on the growler tester to

check for short circuits. While slowly turning the ar-

mature, support the steel sheet for the armature

core. If the circuit of the armature is shorted, the

steel sheet will vibrate, causing it to move towards

the core. When the steel sheet has moved or vi-

brated, replace the armature.

5) Use a circuit tester to touch the probe of one side

to the commutator segment, and the other probe to

the shaft. If there is continuity, replace the arma-

ture.

(A) Dial gauge
(B) V-block

SC-02223

SC-00021

(A)

(B)

(A) Depth of mold
(B) Segment

(C) Mold

(A) Steel sheet
(B) Growler tester

(C)

(B)

(A)

SC-00022

(A)

(B)

SC-00023

SC-00024

SC(STI)-19

Starter

STARTING/CHARGING SYSTEMS

2. YOKE

Make sure that the pole is set at the predetermined

position.

3. OVERRUNNING CLUTCH

Check that there is no wear or damage to the piston

teeth. Replace the overrunning clutch if it is dam-

aged.

Check that it rotates smoothly when rotated in the

correct direction (counterclockwise) and does not

return to the other direction. Replace the overrun-

ning clutch if any fault is found.
CAUTION:

To prevent spilling of grease, do not clean the

overrunning clutch with oil.

4. BRUSH AND BRUSH HOLDER

1) Measure the length of the brush. Replace if it ex-

ceeds service limits or there is abnormal wear or

cracks.
Brush length:

Standard

12.3 mm (0.484 in)

Limit

7.0 mm (0.276 in)

2) Check that the brush moves smoothly in the

brush holder.

3) Measure the brush spring force with a spring

scale. Replace the brush holder if below the service

limit.
Brush spring force:

Standard

15.9 — 19.5 N (1.62 — 1.99 kgf, 3.57 — 4.38

lbf) (When new)

Limit

2.5 N (0.25 kgf, 0.56 lbf)

5. SWITCH ASSEMBLY

Using a circuit tester (set to “ohm”), check that

there is continuity between terminals S and M, and

between terminal S and ground.

Also check to be sure there is no continuity be-

tween M terminal and B.
Resistance between switch assembly termi-

nals:

6. SWITCH ASSEMBLY OPERATION

1) Using a lead wire, connect the terminal S of

switch assembly to positive terminal of battery, and

starter body to ground terminal of battery. The pin-

ion should be forced endwise on shaft.
NOTE:

With the pinion forced endwise on shaft, starter mo-

tor can sometimes rotate because current flows,

through pull-in coil, to motor. This is not a problem.

2) Disconnect the connector from terminal M. Then

using a lead wire, connect the positive terminal of

battery and terminal M, and ground terminal to

starter body.

In this test set up, the pinion should return to its

original position even when it is pulled out with a

screwdriver.

(A) Service limit line
(B) Brush

SC-00102

(A)

(B)

Terminals

Standard

S — M

1 Ω or less

S — Ground

1 Ω or less

M — B

1 MΩ or more

(A) S terminal
(B) M terminal

(C) B terminal

(A) Terminal S
(B) Terminal M

SC-00181

(A)

(B)

(C)

SC-00175

(A)

(B)