Subaru 2003 Legacy User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE2

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 1

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

FUEL INJECTION (FUEL SYSTEMS) FU(H4SO)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4SO)

INTAKE (INDUCTION) IN(H4SO)

MECHANICAL ME(H4SO)

EXHAUST EX(H4SO)

COOLING CO(H4SO)

LUBRICATION LU(H4SO)

SPEED CONTROL SYSTEMS SP(H4SO)

IGNITION IG(H4SO)

STARTING/CHARGING SYSTEMS SC(H4SO)

ENGINE (DIAGNOSTICS) EN(H4SO)

FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD)

INTAKE (INDUCTION) IN(H4SOw/oOBD)

MECHANICAL ME(H4SOw/oOBD)

EXHAUST EX(H4SOw/oOBD)

COOLING CO(H4SOw/oOBD)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 1

G2300GE2

LUBRICATION LU(H4SOw/oOBD)

SPEED CONTROL SYSTEMS SP(H4SOw/oOBD)

IGNITION IG(H4SOw/oOBD)

STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD)

ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD)

STARTING/CHARGING SYSTEMS

SC(H4SO)

Page

1. General Description ....................................................................................2

2. Starter .........................................................................................................6

3. Generator..................................................................................................14

4. Battery.......................................................................................................20

SC(H4SO)-2

STARTING/CHARGING SYSTEMS GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

*: 2.5 L

Item Designation

Starter

Type Reduction type

Vehicle model MT AT

Model M000T83981 M001T86481

Manufacturer Mitsubishi Electric

Voltage and output 12 V —1.0 kW 12 V —1.4 kW

Direction of rotation Counterclockwise (when observed from pinion)

Number of pinion teeth 8 9

No-load characteristics Voltage 11 V

Current 90 A or less

Rotating speed 2,800 rpm or more 2,400 rpm or more

Load characteristics

Voltage 7.5 V 7.7 V

Current 300 A 400 A

Torque 8.6 N·m (0.88 kgf-m, 6.4 ft-lb) 16.0 N·m (1.63 kgf-m, 11.8 ft-lb)

Rotating speed 920 rpm or more 740 rpm or more

Lock characteristics

Voltage 4 V 3.5 V

Current 650 A or less 940 A or less

Torque 14.7 N·m (1.50 kgf-m, 10.8 ft-lb) 28.9 N·m (2.95 kgf-m, 21.3 ft-lb)

or more

Generator

Type Rotating-field three-phase type

Model A002TB6991

Manufacturer Mitubishi Electric

Voltage and output 12 V —90 A

Polarity on ground side Negative

Rotating direction Clockwise (when observed from pulley side.)

Armature connection 3-phase Y-type

Output current 1,500 rpm —36 A or more

2,500 rpm —65 A or more

5,000 rpm —86 A or more

Regulated voltage 14.1 —14.8 V [20°C (68°F)]

Battery Type and capacity For Europe/Latin

America

MT: 12 V —48 AH (55D23L)

AT: 12 V —52 AH (65D23L)

AT: 12 V —52 AH (75D23L)*

Others 12 V —27 AH (34B19L)

SC(H4SO)-3

STARTING/CHARGING SYSTEMS

GENERAL DESCRIPTION

B: COMPONENT

1. STARTER

(1) Sleeve bearing (7) Internal gear ASSY (13) Armature

(2) Front bracket (8) Shaft ASSY (14) Brush holder

(3) Lever set (9) Gear ASSY (15) Brush

(4) Magnet switch ASSY (10) Ball (16) Sleeve bearing

(5) Stopper set (11) Packing (17) Rear bracket

(6) Over running clutch (12) Yoke

SC-00146

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 ) (10)

(11)

(12)

(13)

(14)

(15) (16)

(17)

SC(H4SO)-4

STARTING/CHARGING SYSTEMS GENERAL DESCRIPTION

2. GENERATOR

(1) Pulley nut (7) Bearing (13) Terminal

(2) Pulley (8) Stator coil

(3) Front cover (9) IC regulator with brush Tightening torque: N·m (kgf-m, ft-lb)

(4) Ball bearing (10) Brush T1: 4.7 (0.48, 3.5)

(5) Bearing retainer (11) Rectifier T2: 108 (11.0, 80)

(6) Rotor (12) Rear cover

SC-00163

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 7 )

( 8 )

( 9 )

(10)

(11)

(12)

(13)

SC(H4SO)-5

STARTING/CHARGING SYSTEMS

GENERAL DESCRIPTION

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or dirt.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Be careful not to burn your hands, because each

part in the vehicle is hot after running.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Placeshop jacks or safetystandsat the specified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect ground ca-

ble terminal.

SC(H4SO)-6

STARTING/CHARGING SYSTEMS STARTER

2. Starter

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the air cleaner case.

<Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner

Case.>

3) Remove the air cleaner case stay.

•MT vehicles

•AT vehicles

4) Disconnect the connector and terminal from

starter.

5) Remove the starter from transmission.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

50 N·m (5.1 kgf-m, 37 ft-lb)

FU-00009

SC-00004

SC-00005

(A) Terminal

(B) Connector

SC-00006

( A )

( B )

SC-00007

SC(H4SO)-7

STARTING/CHARGING SYSTEMS

STARTER

C: DISASSEMBLY

1. STARTER ASSEMBLY

1) Loosen nut which holds terminal M of switch as-

sembly, and disconnect connector.

2) Remove bolts which hold switch assembly, and

remove switch assembly, plunger and plunger

spring from starter as a unit.

NOTE:

Be careful because pinion gap adjustment washer

may sometimes be used on the mounting surface

of switch assembly.

3) Remove both through-bolts and brush holder

screws, and detach rear bracket and brush holder.

NOTE:

Before removal, confirm the attachment locations

of brush holder and rear bracket.

4) Remove armature and yokefrom thefrontbrack-

et.

(A) Terminal M

(B) Terminal B

(A) Switch ASSY

(B) Plunger

SC-00148

( A )

( B )

( C )

SC-00149

( A )

( B )

(A) Brush holder

(B) Rear bracket

(A) Armature

(B) Ball

(D) Front bracket

SC-00150

( A ) ( B )

SC-00151

( A )

( B )

( C )

( D )

SC(H4SO)-8

STARTING/CHARGING SYSTEMS STARTER

5) Remove packing A, three planetary gears, pack-

ing B and plate.

NOTE:

Before removal, confirm the inserting location of

packing A.

6) Remove shaft assembly and overrunning clutch

as a unit.

NOTE:

Before removal, confirm the following:

•Lever direction

•Internal gear assembly position

7) Remove overrunningclutch from shaft assembly

as follows:

(1) Remove stopper from ring by lightly tapping

the stopper with an appropriate tool (such as a

socket).

(2) Remove ring, stopper and clutch from shaft.

2. BRUSH HOLDER

Slightly open the metal fitting holding the insulating

plate to the brush holder. Remove the insulating

plate.

NOTE:

The brush and spring can be easily removed from

the brush holder at this time.

(A) Packing A

(B) Planetary gear

(D) Packing B

(A) Lever

(B) Shaft ASSY

(D) Internal gear ASSY

SC-00152

( D )

( C )

( B )

( A )

SC-00153

( A )

( B ) ( C )

( D )

(A) Socket wrench

(B) Ring

(D) Stopper

(A) Brush holder

(B) Insulating plate

SC-00014

( A )

( B )

( C )

( D )

SC-00154

( A )

( B )

( C )

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