1999 SUBARU LEGACY Service Repair Manual

1. Starter
A: MT VEHICLES
1. MODEL: TN128000-8311
B6M0412B
(1) Front ball bearing
(2) Armature
(3) Rear ball bearing
(4) O-ring
(5) Yoke
(6) Brush spring
(7) Brush holder
(8) End frame(9) Screw & washer
(10) Cover
(11) Through bolt
(12) Screw & washer
(13) Starter housing
(14) Overrunning clutch
(15) Steel ball
(16) Spring(17) Retainer
(18) Roller
(19) Idle gear
(20) Nut
(21) Spring washer
(22) Magnet switch
(23) Nut
4
6-1[C1A1]COMPONENT PARTS
1. Starter

B: AT VEHICLES
1. MODEL: TN128000-8321
B6M0413B
(1) Front ball bearing
(2) Armature
(3) Rear ball bearing
(4) O-ring
(5) Yoke
(6) Brush spring
(7) Brush holder
(8) End frame(9) Cover
(10) Screw & washer
(11) Through bolt
(12) Screw & washer
(13) Starter housing
(14) Overrunning clutch
(15) Steel ball
(16) Spring(17) Retainer
(18) Roller
(19) Idle gear
(20) Nut
(21) Spring washer
(22) Magnet switch
(23) Nut
5
[C1B1]6-1COMPONENT PARTS
1. Starter

2. Generator
B6M0414B
(1) Pulley nut
(2) Pulley
(3) Front cover ASSY
(4) Ball bearing
(5) Bearing retainer
(6) Screw
(7) Rotor
(8) Stator coil
(9) IC regulator ASSY(10) Condenser
(11) Diode ASSY
(12) Bolt
(13) Bolt
(14) Brush holder ASSY
(15) Rear cover
(16) BAT. terminal
(17) Nut
(18) Bolt(19) Through bolt
Tightening torque: N´m (kg-m, ft-lb)
T1:
3.1 Ð 4.4 (0.32 Ð 0.45, 2.3 Ð
3.3)
T2:63.7 Ð 83.4 (6.5 Ð 8.5, 47.0
Ð 61.5)
6
6-1[C200]COMPONENT PARTS
2. Generator

1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
B2M1723
2) Remove air intake chamber. [W18A0].>
S6M0007
3) Remove air intake chamber stay. (AT vehicles
only)
S6M0023
4) Remove bolt which installs hill holder cable
bracket. (2200 cc MT model with hill holder)
B6M0891
5) Disconnect connector and terminal from starter.
S6M0002A
(A) Terminal
(B) Connector
6) Remove starter from transmission.
G2M0309
7) Installation is in the reverse order of removal.
Tightening torque:
50
±4 N´m (5.1±0.4 kg-m, 37±2.9 ft-lb)
G2M0309
7
[W1A0]6-1SERVICE PROCEDURE
1. Starter

B: TEST
1. MAGNETIC SWITCH
CAUTION:
IThe following magnetic switch tests should
be performed with specified voltage applied.
IEach test should be conducted within 3 to 5
seconds. Power to be furnished should be one-
half the rated voltage.
1) Pull-in test
Connect two battery negative leads onto magnetic
switch body and terminal C respectively. Then con-
nect battery positive lead onto terminal 50. Pinion
should extend when lead connections are made.
B6M0415A
2) Holding-in test
Disconnect lead from terminal C with pinion
extended. Pinion should be held in the extended
position.
B6M0416A
3) Return test
Connect two battery negative leads onto terminal
50 and onto switch body respectively. Then con-
nect battery positive lead onto terminal C. Next,
disconnect lead from terminal 50. Pinion should
return immediately.
B6M0417A
2. PERFORMANCE TEST
The starter is required to produce a large torque
and high rotating speed, but these starter charac-
teristics vary with the capacity of the battery. It is
therefore important to use a battery with the speci-
fied capacity whenever testing the starter.
The starter should be checked for the following
three items:
INo-load test
Measure the maximum rotating speed and current
under a no-load state.
ILoad test
Measure the magnitude of current needed to gen-
erate the specified torque and rotating speed.
IStall test
Measure the torque and current when the armature
is locked.
8
6-1[W1B1]SERVICE PROCEDURE
1. Starter

1) No-load test
Run single starter under no-load state, and mea-
sure its rotating speed, voltage, and current, using
the specified battery. Measured values must meet
the following standards:
No-load test (Standard):
Voltage/Current
11 V/90 A, or more
Rotating speed
TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
B6M0418A
2) Load test (For reference)
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 rotat-
ing speed under the specified voltage and current
conditions while controlling braking force applied to
starter.
CAUTION:
Change engagement position of overrunning
clutch and make sure it is not slipping.
Load test (Standard):
TN128000-8311
Voltage/Load
8 V/9.8 N´m (1.0 kg-m, 7.2 ft-lb)
Current/Speed
280 A max./900 rpm min.
TN128000-8321
Voltage/Load
8 V/13.7 N´m (1.4 kg-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
B6M0419A
3) Stall test
Using the same test equipment used for load test,
apply brake to lock starter armature. Then mea-
sure voltage, current, and torque values.
Measured values must meet the following stan-
dard.
Stall test (Standard):
TN128000-8311
Voltage/Current
5 V/800 A, or less
Torque
27.5 N´m (2.8 kg-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Current
5 V/1,050 A, or less
Torque
27.5 N´m (2.8 kg-m, 20.3 ft-lb) min.
B6M0420A
NOTE:
Low rotating speed or excessive current during no-
load test may be attributable to high rotating resis-
tance of starter due to improper assembling.
Small current and no torque during stall test may
be attributable to excessive contact resistance
between brush and commutator; whereas, normal
current and insufficient torque may be attributable
to shorted commutator or poor insulation.
Starter can be considered normal if it passes no-
load and stall tests; therefore, load test may be
omitted.
C: DISASSEMBLY
1) Disconnect lead wire from magnetic switch.
B6M0421A
9
[W1C0]6-1SERVICE PROCEDURE
1. Starter

2) Remove through-bolts from end frame.
B6M0422A
3) Remove yoke from magnetic switch.
B6M0423A
4) Remove screws securing end frame to brush
holder.
B6M0424A
5) Separate yoke from end frame.
B6M0425A
6) Remove brush by lifting up positive (+) side
brush spring using long-nose pliers.
CAUTION:
Be careful not to damage brush and commuta-
tor.
B6M0426A
7) Remove armature from yoke.
CAUTION:
Be careful not to drop armature.
B6M0427A
8) Remove screws securing magnetic switch to
housing.
B6M0428A
10
6-1[W1C0]SERVICE PROCEDURE
1. Starter

9) Remove housing from magnetic switch.
B6M0429A
10) Remove clutch from housing.
B6M0430A
11) Take out steel ball from clutch.
CAUTION:
Be careful not to lose steel ball.
B6M0431A
12) Remove idle gear from housing.
B6M0432A
13) Remove retainer and roller from housing.
CAUTION:
Be careful not to drop retainer and roller.
B6M0433A
14) Remove coil spring from magnetic switch.
B6M0434A
D: INSPECTION
1. ARMATURE
1) Check commutator for any sign of burns of
rough surfaces or stepped wear. If wear is of a
minor nature, correct it by using sand paper.
2) Run-out test
Check the commutator run-out and replace if it
exceeds the limit.
Commutator run-out:
Standard
0.02 mm (0.0008 in), or less
Service limit
Less than 0.05 mm (0.0020 in)
G6M0038
11
[W1D1]6-1SERVICE PROCEDURE
1. Starter