Subaru Impreza 3 / Impreza WRX / Impreza WRX STI. Manual - part 114

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STARTING/CHARGING SYSTEMS

8) Remove seal rubber (A), plate (B), and seal rub-

ber (C).

9) Lightly tap the starter housing assembly with a

plastic hammer as shown in the figure, and remove

the  overrunning  clutch,  internal  gear  assembly,

shaft and shift lever together as one unit.

10) Use  the  following  procedures  to  remove  the

overrunning clutch from the shaft.

(1) Use an appropriate tool (such as a fit socket

wrench),  and  remove  the  stopper  from  snap

ring by lightly tapping the stopper with a plastic

hammer.

(2) Remove  snap  ring  (A)  from  the  shaft,  and

remove stopper (B).

(A)

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(B)

(C)

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(A) Appropriate tool
(B) Snap ring

(C) Shaft
(D) Stopper

(A)

(B)

(C)

(D)

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(A)

(B)

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STARTING/CHARGING SYSTEMS

(3) Remove  the  overrunning  clutch  from  the

shaft.

11) Separate the internal gear assembly and shaft.

D: ASSEMBLY

1. STI MODEL

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 as-

sembly.

(3) Install the snap ring to shaft.

NOTE:

Use new snap rings.

(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

(7) Install the starter plate.

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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 le-

ver.
Grease:

DENSO HL50

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.

(3) Pass stopper (B) through the shaft, and at-

tach snap ring (A).

NOTE:

Use new snap rings.

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

snap ring (A).

4) Install the armature to the internal gear assem-

bly.

5) Attach the two brushes wired to the yoke assem-

bly 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.

(A)

(B)

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(A)

(B)

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(A)

(B)

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6) Install the yoke assembly and brush holder as-

sembly as a single unit to the armature.
NOTE:

Spread  the  brush  with  your  fingers,  being  careful

not to damage the brush.

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)

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)

10) Connect  terminal  M  (A)  to  magnet  switch  as-

sembly.
Tightening torque:

10 N·m (1.0 kgf-m, 7.4 ft-lb)

2. EXCEPT FOR STI MODEL

1) Apply grease to the shaft sliding surfaces of the

internal gear assembly.
Grease:

Multemp #6129 or equivalent

2) Assemble the shaft to the internal gear assem-

bly.

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(A)

(B)

(A)

(B)

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(A)

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