Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Starter

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TESTING



Switch Assembly

See Figures 1 and 2

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Fig. Fig. 1: Terminal designation on starter



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Fig. Fig. 2: Measure the pinion gap

  1. Connect terminal S of starter switch to the positive terminal of the battery using a lead wire or equivalent.
  2.  
  3. Connect the starter body to the negative terminal of the battery.
  4.  
  5. If the switch assembly is working correctly, the pinion should be be forced out. If the starter motor rotates, this is OK. Sometimes current will flow through the pull in coil to the motor and cause this.
  6.  
  7. With the pinion forced outward, measure the pinion gap. It should be between 0.02-0.08 in. (0.5-2.0mm).
  8.  
  9. Unfasten all connections.
  10.  
  11. Disconnect the wire at terminal M , and attach a lead wire or equivalent between terminal M and the battery positive terminal.
  12.  
  13. Connect a ground lead between the stater body and the negative terminal of the battery.
  14.  
  15. If the switch assembly is functioning correctly, the pinion should return it its original position.
  16.  

Performance

See Figure 3

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Fig. Fig. 3: Schematic for testing the starter

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.  

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.  

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.  

REMOVAL & INSTALLATION



See Figures 4, 5 and 6

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Fig. Fig. 4: Unfasten the power wire and signal wire from the starter



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Fig. Fig. 5: Remove the retaining bolts from the sides of the starter



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Fig. Fig. 6: With the bolts removed, lift the starter out

  1. Disconnect the negative battery cable, followed by the positive cable.
  2.  
  3. 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.
  4.  
  5. Remove the starter attaching bolts (nuts) and pull the starter away from the engine and out.
  6.  

To install:
  1. Install the starter and tighten the attaching bolts to 34-40 ft. lbs. (46-54 Nm). Tighten the nuts to 22-27 ft. lbs. (30-36 Nm).
  2.  
  3. Connect the wiring harness.
  4.  
  5. Connect the positive battery cable, followed by the negative battery cable.
  6.  

MAGNETIC SWITCH REPLACEMENT



On all engines except the 1.2L and 1.6L, the magnetic switch is an integral part of the starter housing. The starter must be completely disassembled to gain access to the switch.

1.2L and 1.6L Engines
  1. With the starter removed from the vehicle, loosen the magnetic switch nut to remove the connecting wire.
  2.  
  3. Remove the magnetic switch by removing the attaching bolts.
  4.  
  5. Separate the torsion spring from the switch.
  6.  

To install:
  1. Check conductivity between terminal S (the smaller post) and the switch body. If none, replace the switch.
  2.  
  3. Check conductivity between terminal M (the large post) and terminal S . If none, replace the switch.
  4.  
  5. With the plunger pushed inward, check conductivity between terminals M and B . If none, replace the switch.
  6.  
  7. Assemble the switch with the torsion spring and install on the starter.
  8.  
  9. Insert and tighten the switch attaching bolts to 5-6 ft. lbs. (6-8 Nm).
  10.  
  11. Install the connecting wire and the nut securely.
  12.  
  13. Install the starter in the vehicle.
  14.  

 
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