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)
T1
T1
T2

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-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
(C) Terminal S
(A) Switch ASSY
(B) Plunger
SC-00148
( A )
( B )
( C )
SC-00149
( A )
( B )
(A) Brush holder
(B) Rear bracket
(A) Armature
(B) Ball
(C) Yoke
(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
(C) Plate
(D) Packing B
(A) Lever
(B) Shaft ASSY
(C) Overrunning clutch
(D) Internal gear ASSY
SC-00152
( D )
( C )
( B )
( A )
SC-00153
( A )
( B ) ( C )
( D )
(A) Socket wrench
(B) Ring
(C) Shaft
(D) Stopper
(A) Brush holder
(B) Insulating plate
(C) Metal fitting
SC-00014
( A )
( B )
( C )
( D )
SC-00154
( A )
( B )
( C )