2004 SUBARU FORESTER Service Repair Manual

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Page 1089 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-14
STARTING/CHARGING SYSTEM
Starter
Current / Speed
MT model
300 A / 870 rpm or more
AT model
400 A / 710 rpm or more
3) Lock test
With the starter stalled, or not rotating, measure the
tor

Page 1090 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-15
STARTING/CHARGING SYSTEM
Generator
3. Generator
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the connector and terminal from
generator.
Non-turbo model
Turbo m

Page 1091 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-16
STARTING/CHARGING SYSTEM
Generator
C: DISASSEMBLY
1) Remove the four through-bolts.
2) Heat the portion (A) of rear cover to 50°C
(122°F) with heater drier.
3) Then insert the tip of a f

Page 1092 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-17
STARTING/CHARGING SYSTEM
Generator
6) Remove the bearing from rotor using a bearing
puller.
7) Unsolder connection between rectifier and stator
coil to remove the stator coil.
CAUTION:
Do

Page 1093 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-18
STARTING/CHARGING SYSTEM
Generator
10) Remove the rectifier as follows.
(1) Remove the bolts which secure the rectifier.
(2) Remove the cover of terminal B.
(3) Remove the nut of terminal

Page 1094 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-19
STARTING/CHARGING SYSTEM
Generator
E: INSPECTION
1. DIODE
CAUTION:
Never use a mega tester (measuring use for
high voltage) or any other similar measure for
this test; otherwise, the dio

Page 1095 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-20
STARTING/CHARGING SYSTEM
Generator
3. STARTOR
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

Page 1096 of 2870

SUBARU FORESTER 2004 Service Repair Manual SC(H4SO)-21
STARTING/CHARGING SYSTEM
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) cable after discon-
necting the ground (−) cable of battery.
2) Remove the flange nuts from battery

SC(H4SO)-21
STARTING/CHARGING SYSTEM
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) cable after discon-
necting the ground (−) cable of battery.
2) Remove the flange nuts from battery rods, and
then take off the battery holder.
3) 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 then apply
grease to retard formation of corrosion.
Connect the positive (+) cable of battery and then
the ground (−) cable of battery.
C: INSPECTION
WARNING:
Electrolyte has toxicity; be careful handling
the fluid.
Avoid contact with skin, eyes or clothing. Es-
pecially at contact with eyes, blush with water
for 15 minutes and get prompt medical atten-
tion.
Batteries produce explosive gasses. 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 the 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 be-
cause a short circuit will be caused.
1. EXTERNAL PARTS:
Check for the existence of dirt or cracks on battery
case, top cover, vent plugs, and terminal posts. 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 the 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
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 [at
20
°C (68°F)]
2) Measuring the specific gravity of the electrolyte
in battery will disclose the state of charge of bat-
tery. The relation between specific gravity and state
of charge is as shown in the figure.
SC-00053
(1) Specific gravity
(2) Complete charge
(3) Charging condition
(4) Specific gravity and state of charge
1.28
1.26
1.24
1.22
1.20
1.18
1.16
1.14
1.12
100%
(%)75% 50% 22% 0%
SC-00094
[20 C (68 F)](1)
(2) (3)
(4)

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