2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE 1 SECTION

FUEL INJECTION (FUEL SYSTEMS) FU(SOHC)

EMISSION CONTROL EC(SOHC)

(AUX. EMISSION CONTROL DEVICES)

INTAKE (INDUCTION) IN(SOHC)

MECHANICAL ME(SOHC)
This service manual has been prepared
to provide SUBARU service personnel
EXHAUST EX(SOHC)
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. COOLING CO
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of LUBRICATION LU
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual SPEED CONTROL SYSTEMS SP
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. IGNITION IG(SOHC)
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. STARTING/CHARGING SYSTEMS SC

ENGINE (DIAGNOSTICS) EN(SOHC)

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830GE2

STARTING/CHARGING SYSTEMS

SC
Page
1. General Description ....................................................................................2
2. Starter .........................................................................................................5
3. Generator ..................................................................................................12
4. Battery.......................................................................................................17
 GENERAL DESCRIPTION
STARTING/CHARGING SYSTEMS

1. General Description
A: SPECIFICATIONS
Item Designation
Type Reduction type
Vehicle type MT vehicles AT vehicles
Model M001T81681 M001T84481
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
Voltage 11 V
No-load charac-
Current 90 A or less
teristics
Starter Rotating speed 2,800 rpm or more 2,400 rpm or more
Voltage 7.5 V 7.7 V
Current 300 A 400 A
Load character-
istics 16.0 N·m (1.63 kg-m, 11.8 ft-lb) or
Torque 8.7 N·m (0.89 kg-m, 6.4 ft-lb) or more
more
Rotating speed 890 rpm or more 740 rpm or more
Voltage 4V 3.5 V
Lock character- Current 780 A or less 940 A or less
istics 15.7 N·m (1.60 kg-m, 11.6 ft-lb) or 28.9 N·m (2.95 kg-m, 21.3 ft-lb) or
Torque
more more
Rotating-field three-phase type, Voltage regulator built-in type, with load
Type
response control system
Model A2TB2891
Manufacturer Mitsubishi Electric
Voltage and output 12 V — 90 A
Polarity on ground side Negative
Generator
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
1,500 rpm — 36 A or more
Output current 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)]

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 GENERAL DESCRIPTION
STARTING/CHARGING SYSTEMS

B: COMPONENT
1. STARTER

H6M0492C

(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

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 GENERAL DESCRIPTION
STARTING/CHARGING SYSTEMS

2. GENERATOR

H6M0493C

(1) Pulley (5) Rotor (9) Brush

(2) Front cover (6) Bearing (10) Rectifier
(3) Ball bearing (7) Stator coil (11) Rear cover
(4) Bearing retainer (8) IC regulator with brush (12) Terminal

C: CAUTION • Be careful not to burn your hands, because each

• Wear working clothing, including a cap, protec- part in the vehicle is hot after running.
tive goggles, and protective shoes during opera- • Be sure to tighten fasteners including bolts and
tion. nuts to the specified torque.
• Remove contamination including dirt and corro- • Place shop jacks or safety stands at the specified
sion before removal, installation or disassembly. points.
• Keep the disassembled parts in order and pro- • Before disconnecting electrical connectors of
tect them from dust or dirt. sensors or units, be sure to disconnect negative
• Before removal, installation or disassembly, be terminal from battery.
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.

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 STARTER
STARTING/CHARGING SYSTEMS

2. Starter 5) Disconnect connector and terminal from starter.

A: REMOVAL
1) Disconnect battery ground cable.

S6M0002A

(A) Terminal
G6M0095 (B) Connector
2) Remove air cleaner case. (Non-Turbo Model)
6) Remove starter from transmission.

B6M1221
EN1007
3) Remove intercooler. (Turbo Model) <Ref. to
IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
4) Remove air cleaner case stay. (Non-Turbo Mod-
el)
• MT vehicles

EN0369
• AT vehicles

EN0370

SC-5
 STARTER
STARTING/CHARGING SYSTEMS

B: INSTALLATION 3) Remove both through-bolts and brush holder

Install in the reverse order of removal. screws, and detach rear bracket and brush holder.
Tightening torque:
50 N·m (5.1 kgf-m, 37 ft-lb)

H6M0494B

(A) Brush holder

EN1007
(B) Rear bracket
C: DISASSEMBLY 4) Remove armature and yoke. Ball used as a
1. STARTER ASSEMBLY bearing will then be removed from the end of arma-
ture.
1) Loosen nut which holds terminal M of switch as-
sembly, and disconnect connector. CAUTION:
2) Remove bolts which hold switch assembly, and Be sure to mark an alignment mark on yoke and
remove switch assembly, plunger and plunger front bracket before removing yoke.
spring from starter as a unit.
CAUTION:
Be careful because pinion gap adjustment
washer may sometimes be used on the mount-
ing surface of switch assembly.

H6M0495B

(A) Front bracket

(B) Yoke
(C) Ball
(D) Awature
S6M0396A

(A) Switch ASSY

(B) Plunger

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 STARTER
STARTING/CHARGING SYSTEMS

5) Remove packing A, three planetary gears, pack- 7) Remove overrunning clutch from shaft assembly
ing B and plate. as follows:
(1) Remove stopper from ring by lightly tapping
a fit tool placed on stopper.
(2) Remove ring, stopper and clutch from shaft.

S6M0397A

(A) Packing A
(B) Planetary gear
S6M0399A
(C) Plate
(D) Packing B (A) Stopper
(B) Tool
6) Remove shaft assembly and overrunning clutch (C) Ring
as a unit. (D) Shaft
CAUTION:
Record the direction of lever before removing. 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.

S6M0398A

(A) Shaft ASSY

(B) Overrunning clutch
(C) Lever

H6M0497B

(A) Brush holder

(B) Insulating plate
(C) Metal fitting

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 STARTER
STARTING/CHARGING SYSTEMS

D: ASSEMBLY 3) Depth of segment mold

Assembly is in the reverse order of disassembly Check the depth of segment mold.
procedures. Do the following: Depth of segment mold:
1) Carefully assemble all parts in the order of as- 0.5 mm (0.020 in)
sembly and occasionally inspect nothing has been
overlooked.
2) Apply grease to the following parts during as-
sembly.
• Front and rear bracket sleeve bearing
• Armature shaft gear
• Outer periphery of plunger
• Mating surface of plunger and lever
• Gear shaft splines
• Mating surface of lever and clutch
• Ball at the armature shaft end S6M0401A
• Internal and planetary gears
(A) Depth of mold
3) After assembling parts correctly, check to be
sure starter operates properly. (B) Segment
(C) Mold
E: INSPECTION
4) Armature short-circuit test
1. ARMATURE Check armature for short-circuit by placing it on
1) Check commutator for any sign of burns of rough growler tester. Hold a hacksaw blade against arma-
surfaces or stepped wear. If wear is of a minor na- ture core while slowly rotating armature. A short-
ture, correct it by using sand paper. circuited armature will cause the blade to vibrate
2) Run-out test and to be attracted to core. If the hacksaw blade is
Check the commutator run-out and replace if it ex- attracted or vibrates, the armature, which is short-
ceeds the limit. circuited, must be replaced or repaired.

Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
Less than 0.10 mm (0.0039 in)

S6M0402A

(A) Iron sheet

(B) Grower

S6M0400A

(A) V-block

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 STARTER
STARTING/CHARGING SYSTEMS

5) Armature ground test 2) Brush movement

Using circuit tester, touch one probe to the commu- Be sure brush moves smoothly inside brush holder.
tator segment and the other to shaft. There should 3) Brush spring force
be no continuity. If there is a continuity, armature is Measure brush spring force with a spring scale. If it
grounded. is less than the service limit, replace brush holder.
Replace armature if it is grounded.
Brush spring force:
Standard
21.6 N (2.2 kg, 4.9 lb) (when new)
Service limit
5.9 N (0.6 kg, 1.3 lb)
5. SWITCH ASSEMBLY
Be sure there is continuity between terminals S and
M, and between terminal S and ground. Use a cir-
cuit tester (set in “ohm”).
G6M0041 Also check to be sure there is no continuity be-
2. YOKE tween terminal M and B.

Make sure pole is set in position. Terminal / Specified resistance:

S — M / Continuity
3. OVERRUNNING CLUTCH S — Ground / Continuity
Inspect teeth of pinion for wear and damage. Re- M — B / No continuity
place if it is damaged. Rotate pinion in direction of
rotation (counterclockwise). It should rotate
smoothly. But in opposite direction, it should be
locked.
CAUTION:
Do not clean overrunning clutch with oil to pre-
vent grease from flowing out.
4. BRUSH AND BRUSH HOLDER
1) Brush length S6M0403
Measure the brush length and replace if it exceeds
6. SWITCH ASSEMBLY OPERATION
the service limit.
Replace if abnormal wear or cracks are noticed. 1) Connect terminal S of switch assembly to posi-
tive terminal of battery with a lead wire, and starter
Brush length: body to ground terminal of battery. Pinion should
Standard be forced endwise on shaft.
12.3 mm (0.484 in)
Service limit CAUTION:
7.0 mm (0.276 in) With pinion forced endwise on shaft, starter
motor can sometimes rotate because current
flows, through pull-in coil, to motor. This is not
a problem.

H6M0496B

(A) Service limit line

(B) Brush

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 STARTER
STARTING/CHARGING SYSTEMS

2) Disconnect connector from terminal M, and con- 8. PERFORMANCE TEST

nect positive terminal of battery and terminal M us-
The starter should be submitted to performance
ing a lead wire and ground terminal to starter body.
tests whenever it has been overhauled, to assure
In this test set up, pinion should return to its original
its satisfactory performance when installed on the
position even when it is pulled out with a screwdriv-
engine.
er.
Three performance tests, no-load test, load test,
and lock test, are presented here; however, if the
load test and lock test cannot be performed, carry
out at least the no-load test.
For these performance tests, use the circuit shown
in figure.

S6M0393A

(A) Terminal S
(B) Terminal M

7. PINION GAP
S6M0395A
1) Measure pinion gap while the pinion is pulled out
as shown in the figure. (A) Variable resistance
Pinion gap: (B) Magnetic switch
0.5 — 2.0 mm (0.020 — 0.079 in) (C) Starter body

1) No-load test
With switch on, adjust the variable resistance to ob-
tain 11 V, take the ammeter reading and measure
the starter speed. Compare these values with the
specifications.
No-load test (Standard):
Voltage / Current
11 V / 90 A max.
S6M0394A Rotating speed
MT vehicles
(A) Pinion 2,800 rpm or more
(B) Gap AT vehicles
(C) Stopper 2,400 rpm or more
If motor is running with the pinion forced endwise
on the shaft, disconnect connector from terminal M
of switch assembly and connect terminal M to
ground terminal (−) of battery with a lead wire.
Next, gently push pinion back with your fingertips
and measure pinion gap.
2) If pinion gap is outside specified range, remove
or add number of adjustment washers used on the
mounting surface of switch assembly until correct
pinion gap is obtained.

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 STARTER
STARTING/CHARGING SYSTEMS

2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.
Load test (Standard):
Voltage / Load
MT vehicles
7.5 V/8.7 N·m (0.89 kg-m, 6.4 ft-lb)
AT vehicles
7.7 V/16.0 N·m (1.63 kg-m, 11.8 ft-lb)
Current / Speed
MT vehicles
300 A/890 rpm or more
AT vehicles
400 A/740 rpm or more
3) Lock test
With starter stalled, or not rotating, measure the
torque developed and current draw when the volt-
age is adjusted to the specified voltage.
Lock test (Standard):
Voltage / Current
MT vehicles
4 V/780 A or less
AT vehicles
3.5 V/940 A or less
Torque
MT vehicles
15.7 N·m (1.60 kg-m, 11.6 ft-lb) or more
AT vehicles
28.9 N·m (2.95 kg-m, 21.3 ft-lb) or more

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 GENERATOR
STARTING/CHARGING SYSTEMS

3. Generator • Turbo Model

A: REMOVAL
1) Disconnect battery ground cable.

EN0048
4) Remove front side V-belt.
<Ref. to ME(SOHC)-42, FRONT SIDE BELT, RE-
G6M0095 MOVAL, V-belt.> or <Ref. to ME(DOHC TURBO)-
2) Disconnect connector and terminal from genera- 43, FRONT SIDE BELT, REMOVAL, V-belt.>
tor. 5) Remove bolts which install generator onto brack-
• Non-Turbo Model et.

B2M3105 S6M0352
• Turbo Model
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Check and adjust V-belt tension. <Ref. to
ME(SOHC)-43, INSPECTION, V-belt.> and <Ref.
to ME(DOHC TURBO)-44, INSPECTION, V-belt.>

EN0046
3) Remove V-belt cover.
• Non-Turbo Model

S6M0352

B2M3106

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 GENERATOR
STARTING/CHARGING SYSTEMS

C: DISASSEMBLY
1) Heat the portion (A) of rear cover to 50°C
(122°F) with heater drier.

H6M0498B

(A) Front bracket

B6M0476B (B) Pulley
2) Remove the four through bolts. Then insert the (C) Nut
tip of a flat-head screwdriver into the gap between (D) Rotor
the stator core and front bracket. Pry then apart to
disassemble. 4) Unsolder connection between rectifier and stator
coil to remove stator coil.
CAUTION:
Finish the work rapidly (less than three sec-
onds) because the rectifier cannot withstand
heat very well.

G6M0065
3) Hold rotor with a vise and remove pulley nut.

G6M0068
5) Remove screws which secure IC regulator to
rear cover, and unsolder connection between IC
regulator and rectifier to remove IC regulator.

G6M0066

CAUTION:
When holding rotor with vise, insert aluminum
plates or wood pieces on the contact surfaces
of the vise to prevent rotor from damage.

G6M0069

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 GENERATOR
STARTING/CHARGING SYSTEMS

6) Remove the brushes by unsoldering at the pig- CAUTION:

tails. Grease should not be applied for the rear bear-
ing. Remove oil completely if it is found on the
bearing box.
3) After reassembly, turn the pulley by hand to
check that the rotor turns smoothly.
E: INSPECTION
1. DIODE
CAUTION:
G6M0070 Never use a megger tester (measuring use for
7) Remove the nut and insulating bushing at termi- high voltage) or any other similar measure for
nal B, and remove rectifier. this test; otherwise, the diodes may be dam-
aged.
1) Checking positive diode
Check for continuity between the diode lead and
the positive side heat sink. The positive diode is in
good condition if continuity exists only in the direc-
tion from the diode lead to the heat sink.

S6M0405A

(A) Ractifier
(B) Rear cover
(C) Nut

D: ASSEMBLY S6M0406A
To assemble, reverse order of disassembly.
(A) Diode lead
1) Pulling up brush
(B) Heat sink (Positive side)
Before assembling, press the brush down into the
brush holder with your finger and secure in that po- 2) Checking negative diode
sition by passing a [2 mm (0.08 in) dia. length 4 to Check for continuity between the negative side
5 cm (1.6 to 2.0 in)] wire (A) through the hole shown heat sink and diode lead. The negative diode is in
in the figure. good condition if continuity exists only in the direc-
CAUTION: tion from the heat sink to the diode lead.
Be sure to remove the wire after reassembly.

S6M0407A
S6M0411A
2) Heat the bearing box in the rear bracket [50 to (A) Diode lead
60°C (122 to 140°F)] and press the rear bearing (B) Heat sink (Negative side)
into the rear bracket.

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 GENERATOR
STARTING/CHARGING SYSTEMS

2. ROTOR (2) The rear bearing can be removed by using

common bearing puller.
1) Slip ring surface
Inspect slip rings for contamination or any rough-
ness of the sliding surface. Repair slip ring surface
using a lathe or sand paper.
2) Slip ring outer diameter
Measure slip ring outer diameter. If slip ring is worn
replace rotor assembly.
Slip ring outer diameter:
Standard
22.7 mm (0.894 in)
G6M0077
Limit
22.1 mm (0.870 in) 3. STATOR
3) Continuity test 1) Continuity test
Check resistance between slip rings using circuit Inspect stator coil for continuity between each end
tester. of the lead wires. If there is no continuity between
If the resistance is not within specification, replace individual lead wires, the lead wire is broken, and
rotor assembly. so replace stator assembly.
Specified resistance:
Approx. 2.7 — 3.2 Ω

G6M0078
2) Insulation test
G6M0075
Inspect stator coil for continuity between stator core
and each end of the lead wire. If there is continuity,
4) Insulation test
the stator coil is grounded, and so replace stator
Check continuity between slip ring and rotor core or assembly.
shaft. If continuity exists, the rotor coil is grounded,
and so replace rotor assembly.

G6M0079

G6M0076
5) Ball bearing (rear side)
(1) Check rear ball bearing. Replace if it is noisy
or if rotor does not turn smoothly.

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 GENERATOR
STARTING/CHARGING SYSTEMS

4. BRUSH 5. BEARING (FRONT SIDE)

1) Measure the length of each brush. If wear ex- 1) Check front ball bearing. If resistance is felt while
ceeds the service limit, replace the brush. Each rotating, or if abnormal noise is heard, replace the
brush has the service limit mark (A) on it. ball bearing.
2) Replacing front bearing
Brush length:
(1) Remove front bearing retainer.
Standard
18.5 mm (0.728 in) (2) Closely install a fit tool on the bearing inner
race. Press the bearing down out of front brack-
Service limit
et with a hand press or vise. A socket wrench
5.0 mm (0.197 in)
can serve as the tool.

H6M0499B
2) Checking brush spring for proper pressure S6M0409A
Using a spring pressure indicator, push the brush (A) Front bracket
into the brush holder until its tip protrudes 2 mm (B) Socket wrench
(0.08 in). Then measure the pressure of the brush
spring. If the pressure is less than 2.648 N (270 g, (3) Set a new bearing and closely install a fit
9.52 oz), replace the brush spring with a new one. tool on the bearing outer race. Press the bearing
The new spring must have a pressure of 4.609 to down into place with a hand press or vise. A
5.786 N (470 to 590 g, 16.58 to 20.81 oz). socket wrench can serve as the tool.
(4) Install front bearing retainer.

G6M0143

S6M0410A

(A) Bearing
(B) Socket wrench
(C) Front bracket

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 BATTERY
STARTING/CHARGING SYSTEMS

4. Battery C: INSPECTION
A: REMOVAL WARNING:
• Electrolyte has toxicity; be careful handling
1) Disconnect the positive (+) terminal after discon- the fluid.
necting the negative (−) terminal of battery.
• Avoid contact with skin, eyes or clothing. Es-
2) Remove flange nuts from battery rods and take pecially at contact with eyes, blush with water
off battery holder. 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.
B6M1506 • Do not let battery fluid contact eyes, skin,
3) Remove battery. fabrics, or paint-work because battery fluid is
corrosive acid.
B: INSTALLATION • To lessen the risk of sparks, remove rings,
Install in the reverse order of removal. metal watch-bands, and other metal jewelry.
Tightening torque: Never allow metal tools to contact the positive
3.4 N·m (0.35 kgf-m, 2.5 ft-lb) battery terminal and anything connected to it
while you are at the same time in contact with
NOTE: any other metallic portion of the vehicle be-
• Clean battery cable terminals and apply grease cause a short circuit will be caused.
to retard the formation of corrosion.
• Connect the positive (+) terminal of battery and 1. EXTERNAL PARTS:
then the negative (−) terminal of the battery. Check for the existence of dirt or cracks on the bat-
tery 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 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:

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 BATTERY
STARTING/CHARGING SYSTEMS

S20 = St + 0.0007 × (t − 20) 2. CHECK HYDROMETER FOR STATE OF

S20: Specific gravity corrected at electrolyte CHARGE
temperature of 20°C
St : Measured specific gravity Hydrometer
State of charge Required action
t : Measured temperature (°C) indicator
Determine whether or not battery must be Green dot Above 65% Load test
charged, according to corrected specific Dark dot Below 65% Charge battery
gravity. Replace battery*
Clear dot Low electrolyte
Standard specific gravity: 1.220 — 1.290 [at (If cranking complaint)
20°C (68°F)] *: Check electrical system before replacement.

3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approximately 1/10 of battery's
ampere-hour rating.
4. QUICK CHARGING
Quick charging is a method in which the battery is
charged in a short period of time with a relatively
G6M0103 large current by using a quick charger.
2) Measuring the specific gravity of the electrolyte Since a large current flow raises electrolyte temper-
in the battery will disclose the state of charge of the ature, the battery is subject to damage if the large
battery. The relation between the specific gravity current is used for prolonged time. For this reason,
and the state of charge is as shown in figure. the quick charging must be carried out within a cur-
rent range that will not increase the electrolyte tem-
D: MEASUREMENT perature above 40°C (104°F).
WARNING: It should be also remembered that the quick charg-
• Do not bring an open flame close to the bat- ing is a temporary means to bring battery voltage
tery at this time. up to a fair value and, as a rule, a battery should be
charged slowly with a low current.
CAUTION:
• Prior to charging, corroded terminals should CAUTION:
be cleaned with a brush and common baking • Observe the items in 1. NORMAL CHARGING.
soda solution. • Never use more than 10 amperes when
• Be careful since battery electrolyte overflows charging the battery because that will shorten
while charging the battery. battery life.
• Observe instructions when handling battery
charger.
• Before charging the battery on vehicle, dis-
connect battery ground terminal. Failure to fol-
low this rule may damage alternator's diodes or
other electrical units.
1. JUDGMENT OF BATTERY IN CHARGED
CONDITION
1) Specific gravity of electrolyte is held at a specific
value in a range from 1.250 to 1.290 for more than
one hour.
2) Voltage per battery cell is held at a specific value
in a range from 2.5 to 2.8 volts for more than one
hour.

SC-18