Subaru Legacy (2005 year). Manual - part 102

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STARTING/CHARGING SYSTEMS

Generator

3. STATOR

1) Continuity test
Inspect the stator coil for continuity between each
end of the lead wires. If resistance is 1 M

Ω or more,

the lead wire is broken, and so replace the stator
assembly.

2) Insulation test
Inspect the stator coil for continuity between stator
core and each end of lead wire. If resistance is 1 

Ω

or less, the stator coil is grounded, and so replace
the stator assembly.

4. BRUSH

1) Measure the length of each brush. If wear ex-
ceeds the service limit, replace the brush. Each
brush has the service limit mark (A) on it.

Brush length:

Service limit (1)

5.0 mm (0.197 in)

Standard (2)

18.5 mm (0.728 in)

2) Checking brush spring for proper pressure
Using a spring pressure indicator, push the brush
into the brush holder until its tip protrudes 2 mm
(0.08 in). Then measure the pressure of brush
spring. If the pressure is less than 2.648 N (270 gf,
9.52 ozf), replace the brush spring with a new one.
The new spring must have a pressure of 4.609 to
5.786 N (470 to 590 gf, 16.58 to 20.810 ozf).

5. BEARING (FRONT SIDE)

Check the front ball bearing. If the resistance is felt
while rotating, or if abnormal noise is heard, re-
place the ball bearing

(A) Stator

(A)

SC-00047

SC-00048

SC-00162

(A)

(1)

(2)

SC-00093

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STARTING/CHARGING SYSTEMS

Battery

4. Battery

A: REMOVAL

1) Disconnect the positive (+) terminal after discon-
necting the negative (

−) terminal of battery.

2) Remove the battery cable holder from battery
rod.
3) Remove the flange nuts from battery rods and
take off battery holder.

4) Remove the battery.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

3.4 N

⋅

m (0.35 kgf-m, 2.5 ft-lb)

NOTE:
• Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
• Connect the positive (+) terminal, and then con-
nect the negative (

−) terminal of battery.

• Initial diagnosis of electronic throttle control is
performed after battery installation. For this reason,
start the engine after 10 seconds or more have
elapsed since the ignition switch was turned to ON.

C: INSPECTION

WARNING:
• Electrolyte has toxicity; be careful of han-
dling the fluid.
• Avoid contact with skin, eyes or clothing. Es-
pecially at contact with eyes, flush with water
for 15 minutes and get prompt medical atten-
tion.
• Batteries produce explosive gases. Keep
sparks, flame, cigarettes away.
• Ventilate when charging or using in enclosed
space.
• For safety, in case an explosion does occur,
wear eye protection or shield your eyes when
working near any battery. Never lean over a bat-
tery.
• Do not let battery fluid contact eyes, skin,
fabrics, or paint-work because battery fluid is
corrosive acid.

• To lessen the risk of sparks, remove rings,
metal watch-bands, and other metal jewelry.
Never allow metal tools to contact the positive
battery terminal and anything connected to it
while you are at the same time in contact with
any other metallic portion of the vehicle. This
may cause short circuit.

1. EXTERNAL PARTS

Check the battery case, top cover, vent plugs, and
terminal posts for dirt or cracks. If necessary, clean
with water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.

2. ELECTROLYTE LEVEL

Check the electrolyte level in each cell. If the level
is below MIN level, bring the level to MAX level by
pouring distilled water into the battery cell. Do not
fill beyond MAX level.

3. SPECIFIC GRAVITY OF ELECTROLYTE

1) Measure specific gravity of electrolyte using a
hydrometer and a thermometer.
Specific gravity varies with temperature of electro-
lyte so that it must be corrected at 20

°C (68°F) us-

ing the following equation:

S

20

 = St + 0.0007 

×

 (t 

−

 20)

S

20

: Specific gravity corrected at electrolyte 

temperature of 20

°

C (68

°

F)

St: Measured specific gravity
t: Measured temperature (

°

C)

Determine whether or not battery must be 
charged, according to corrected specific 
gravity.
Standard specific gravity: 1.220 — 1.290 
[20

°

C (68

°

F)

2) Measuring the specific gravity of the electrolyte
in the battery will disclose the state of charge of the
battery. The relation between specific gravity and
state of charge is as shown in the figure.

SC-00180

SC-00054

0

10

20

30

40

50

60

70

80

90

100

1.12

1.20

1.16

1.24

1.28

1.22

1.08

1.04

Amount of discharge (%)

Specific gravity ( C)

Battery with standard specific gravity 1,280 (20 C)

Good

Need to charge

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STARTING/CHARGING SYSTEMS

Battery

D: MEASUREMENT

WARNING:
Do not bring an open flame close to the battery
at this time.

CAUTION:
• Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
• Be careful since battery electrolyte overflows
while charging the battery.
• Observe instructions when handling the bat-
tery charger.
• Before charging the battery on the vehicle,
disconnect the battery ground terminal to pre-
vent damage of generator diodes or other elec-
trical units.

1. JUDGMENT OF BATTERY IN CHARGED 
CONDITION

1) Specific gravity of electrolyte should be held
within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a spe-
cific value in a range from 2.5 to 2.8 V for more than
one hour.

2. CHECK HYDROMETER FOR STATE OF 
CHARGE

3. NORMAL CHARGING

Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of battery’s
ampere-hour rating.

4. QUICK CHARGING

Quick charging is a method that the battery is
charged in a short period of time with a relatively
large current by using a quick charger.
Since a large current flow raises electrolyte temper-
ature, the battery is subject to damage if the large
current is used for prolonged time. For this reason,
the quick charging must be carried out within a cur-
rent range that will not increase the electrolyte tem-
perature above 40

°C (104°F).

Also the quick charging is a temporary means to
bring battery voltage up to a fair value and, as a
rule, a battery should be charged slowly with a low
current.

CAUTION:
• Observe the items in 3. NORMAL CHARGING.
• Never use more than 10 A when charging the
battery because it will shorten the battery life.

Hydrometer 

indicator

Charge bat-

tery

Corrective action

Green

Above 65%

Load test

Dark

65% or less

Charge battery

Clear

Low electro-

lyte

Replace battery*

(If cranking is difficult)

* Check electrical system before replacement.

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STARTING/CHARGING SYSTEMS

Battery