Subaru Car 1998-05

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) connector, on Legacy models equipped with a manual transaxle
     
    Air cleaner case and duct
     
    Air cleaner case stay, on Legacy models
     
    Connector and terminal from starter
     
    Retaining bolts and/or nuts
     
    Starter from transmission
     

  4.  

To install:

  1. Install or connect the following:

    Starter to the transmission
     
    Starter retaining bolts and/or nuts and tighten to 34-40 ft. lbs. (46-54 Nm)
     
    Connector and terminal to starter
     
    Air cleaner case stay, on Legacy models
     
    Air cleaner case and duct
     
    IAT connector, on Legacy models equipped with a manual transaxle
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) connector, on Legacy models equipped with a manual transaxle
     
    Air cleaner case and duct
     
    Air cleaner case stay, on Legacy models
     
    Connector and terminal from starter
     
    Retaining bolts and/or nuts
     
    Starter from transmission
     

  4.  

To install:

  1. Install or connect the following:

    Starter to the transmission
     
    Starter retaining bolts and/or nuts and tighten to 34-40 ft. lbs. (46-54 Nm)
     
    Connector and terminal to starter
     
    Air cleaner case stay, on Legacy models
     
    Air cleaner case and duct
     
    IAT connector, on Legacy models equipped with a manual transaxle
     
    Negative battery cable
     

  2.  



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Fig. Unfasten the power wire and signal wire from the starter-1997



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Fig.



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Fig.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable, followed by the positive cable.
  4.  
  5. Label and disconnect the wiring harness attached to the starter. Remove the battery cable attached. All starter control wires are located on top of the transaxle at the rear of the engine.
  6.  
  7. Remove the starter attaching bolts (nuts) and pull the starter away from the engine and out.
  8.  

To install:

  1. Installation is the reverse of removal. Secure the starter attaching bolts to 34-40 ft. lbs. (46-54 Nm). Tighten the nuts to 22-27 ft. lbs. (30-36 Nm).
  2.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Intake Air Temperature (IAT) connector, on Legacy equipped with a manual transmission
     
    Air cleaner case and duct
     
    Air cleaner case stay, on Legacy
     
    Connector and terminal from starter
     
    Retaining bolts and/or nuts
     
    Starter from transmission
     

  2.  

To install:

  1. Install or connect the following:

    Starter to the transmission
     
    Starter retaining bolts and/or nuts and tighten to 34-40 ft. lbs. (46-54 Nm)
     
    Connector and terminal to starter
     
    Air cleaner case stay, on Legacy
     
    Air cleaner case and duct
     
    IAT connector, on Legacy equipped with a manual transmission
     
    Negative battery cable
     

  2.  

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake chamber, on non turbocharged engine.
  4.  
  5. Remove the intercooler, on turbocharged engine.
  6.  
  7. Remove the air intake chamber stay, on non turbocharged engine.
  8.  
  9. Disconnect the electrical connectors from the starter.
  10.  
  11. Remove the starter retaining bolts. Remove the starter from the vehicle.
  12.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Torque the starter retaining bolts to 37 ft. lbs.
  4.  

Testing & Troubleshooting





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Fig. Schematic for testing the starter-1997



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Fig. Use this illustration as a guide when performing the starter tests-1998-2005

Load Test
  1. Refer to the illustration and connection ammeter, voltmeter and switch.
  2.  
  3. Apply braking torque to the starter.
  4.  
  5. Measure the current draw and starter speed at 7.7 volts.
  6.  
  7. If the starter is functioning correctly, at a load of 7.7 volts and 7 ft. lbs. (10 Nm) of torque, the should be a maximum current draw of 300 amps at 1000 rpm.
  8.  

  1. Perform this test to check maximum output of starter. Use test bench which is able to apply load (brake) to starter. Measure torque value and rotating speed under the specified voltage and current conditions while controlling braking force applied to starter.
  2.  
  3.  
  4. Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within the specifications.
    1. Voltage / Load

      Non-turbo MT vehicles 7.5 V/6.3 ft lbs. (8.6 Nm)
       
      Turbo MT vehicles 8 V/6.9 ft lbs. (9.3 Nm)
       
      AT vehicles 7.7 V/11.8 ft lbs. (16 Nm)
       

    2.  
    3. Current / Speed

      Non-turbo MT vehicles 300 A/920 rpm or more
       
      Turbo MT vehicles: 280 A/860 rpm or more
       
      AT vehicles: 400 A/740 rpm or more
       

    4.  

  5.  

Lock Test
  1. Refer to the illustration and connection ammeter, voltmeter and switch.
  2.  
  3. with the starter stalled, or not rotating, measure the torque developed and the current draw when the voltage is adjusted to 4.0 volts.
  4.  
  5. If the starter is functioning properly, at 4.0 volts, the starter will draw a maximum of 980 amps at a torque of 17 ft. lbs. (23 Nm).
  6.  

  1. Using the same test equipment used for load test, apply brake to lock starter armature. Then measure voltage, current, and torque values.
  2.  
  3. With the starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to the specified voltage.
    1. TN128000-8311 Starter

      Voltage/Current: 5 V/800 A, or less
       
      Torque: 20.3 ft. lbs. (27.5Nm) minimum
       

    2.  
    3. TN128000-8321 Starter

      Voltage/Current: 5 V/1,050 A, or less
       
      Torque: 20.3 ft. lbs. (27.5Nm) minimum
       

    4.  

  4.  

No-Load Test
  1. Refer to the illustration and connection ammeter, voltmeter and switch.
  2.  
  3. With the switch ON, adjust the variable resistance to obtain 11.0 volts.
  4.  
  5. Take an ammeter reading and record the starter speed.
  6.  
  7. If the starter is functioning properly, at 11.0 volts, with a maximum of 90 amps, the starter will be rotating at 3000 rpm.
  8.  

  1. Run single starter under no-load state, and measure its rotating speed, voltage, and current, using the specified battery.
  2.  
  3. With switch on, adjust the variable resistor to obtain 11 V, take the ammeter reading, and then measure the starter speed. Compare these values with the specifications.

    Non-turbo Manual Transmission vehicles: 2,800 rpm or more
     
    Turbo Manual Transmission vehicles: 2,860 rpm or more
     
    Automatic Transmission vehicles: 2,400 rpm or more
     

  4.  

 
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