Subaru Legacy/Outback

1999-2003 of release

Repair and operation of the car

Subaru of Legasi, Autbek
+ Cars Subaru Legacy, Outback
+ Operation manual
+ Routine maintenance
+ Engine
+ Cooling systems, heating
+ Power supply system and release
- Electric equipment of the engine
   Start of the engine from the auxiliary power supply
   Removal/installation, check and service of the battery
   Check of a state and replacement of wires of the battery
   System of ignition - the general information and precautionary measures
   Check of serviceability of functioning of system of ignition
   Removal, installation and check of a condition of the module(s) of ignition
   Check and adjustment of installation of a corner of an advancing of ignition
   Replacement of CKP, CMP and KS sensors
   Service and replacement of spark plugs
   Check of a condition of high-voltage wires (4-cylinder engines)
   System of a charge - the general information and precautionary measures
   Check of a condition of system of a charge
   The generator - the general information, check and service
   Removal, dismantling, assembly and installation of the generator
   System of start - the general information and precautionary measures
   Check of serviceability of functioning of a starter and chain of start
   Nippondenso starter - check and service
   Mitsubishi starters - check and service
+ Manual box and differential
+ Automatic transmission
+ Coupling
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment


Nippondenso starter - check and service

Nippondenso 128000-8321 starter design

1 — the Vtulchaty bearing
2 — the Forward cover
3 — Lever assembly
4 — the Traction relay (the magnetic actuator)
5 — Persistent elements
6 — Obgonnaya the coupling
7 — Reduktornaya assembly
8 — the Shaft of a driving gear wheel
9 — the Driving gear wheel

10 — the Sealant
11 — the Coupling
12 — the Steel ball
13 — the Anchor
14 — the Brush holder
15 — the Bearing
16 — the Back cover
17 — the Through bolt

Removal and installation


1. Disconnect a negative wire from the battery.
2. Remove an airreception chamber (see the Head of the Power supply system and release).
3. Disconnect an electrical wiring (a plait and the tire of grounding) from a starter.

4. Turn out fixing bolts and remove a starter from a transmission dome.

5. Installation is made upside-down. Tighten bolts of fastening of a starter to transmission with the demanded effort (50 Nanometers).

Dismantling and assembly


1. Weaken nuts of fastening of the M plug of the traction relay and disunite the contact socket of an electrical wiring.

A — the Plug M
B — the Plug B
With — the Plug S

2. Turn out fixing bolts and remove the traction relay from a starter in assembly with a plunger and a plunger spring.

 On a basic surface of the actuator the washer of adjustment of a gap of a gear wheel can be established, - try not to drop it!

A — the Traction relay
B — the Plunger

3. Turn out coupling bolts and screws of fastening of the brush holder, then remove a back cover of a starter and the brush holder.

A — the Back cover
B — the Brush holder

4. Take an anchor and the coupling from the stator. Remove the ball established in face part of anchor assembly, - try not to drop it.

 The anchor has considerable weight! Before removal of the coupling mark its provision of rather forward cover!

5. Remove a sealant (A), three planetary gear wheels and a plate.

A — A Sealant
B — Planetary gear wheels
With — the Plate
D — B Sealant

6. Remove in bulk assembled with the obgonny coupling, - try to remember the adjusting provision of lever assembly.

7. Remove the obgonny coupling from a shaft for what, slightly tapping with the suitable tool on an emphasis, remove it from a ring, then take a lock ring, an emphasis and remove the coupling from a shaft.

A — the Face key
B — the Ring
With — the Shaft
D — the Emphasis

8. Assembly is carried out upside-down. Track that all components were established on the regular places. Grease the listed below components with greasing like Esso Beacon 325 Shell Alvania Grease RA:

a) Forward and back bearings;
b) Anchor shaft gear wheel;
c) Plunger surface;
d) Lever surface;
e) Gear wheel shaft grooves;
f) Surface of the lever and obgonny coupling;
g) A ball at an anchor shaft end face;
h) Internal components of planetary transfer.
9. Having finished assembly, make sure of correctness of functioning of a starter.




1. Check a collector for existence of signs of burning or step wear. Insignificant defects can be eliminated by means of a fine-grained emery paper.

2. Lay an anchor in V-shaped prisms and by means of the dial measuring instrument of plunger type estimate the size of a radial beating of a collector. In case of need give assembly to a pro-point.

 Minor defects can be removed from a collector surface by processing with its fine-grained emery paper.

A — the Dial measuring instrument
B — the Prism

3. Check depth of undercutting of isolation between collector lamels, - if the result of measurement makes less than 0.2 mm, make the corresponding adjustment, having used a hacksaw cloth for this purpose.

A — the Lamel
B — Isolation

4. Using a special tester for identification of short-circuited rounds, check anchor windings for existence of signs of short circuit between collector lamels. If short circuit takes place, current in the device will alternate with the return current, and the winding of an anchor will be magnetized. A sign of magnetization of a winding is vibration of a metal plate, subwearable to the checked site.

 Before check it is necessary to remove completely from a surface of windings a coal raid and other deposits.

A — the Iron plate
B — the Directing adaptation

4. Check for breakdown isolation between a collector and the core of an anchor, - the measured resistance has to make not less than 10 megohms.



By means of an ohmmeter check a condition of a winding of excitement of the stator.

Obgonny coupling


1. Attentively examine working surfaces of teeths of the leading and parasitic gear wheels, and also gear wheels of the obgonny coupling. At identification of chips or signs of excessive wear the obgonny coupling is subject to replacement assembled, - in parallel it is necessary to study a condition of a gear wreath of a flywheel.
2. Check freedom of rotation of the obgonny coupling in the direction clockwise, - counterclockwise the coupling should not rotate.

 In order to avoid an effluence of greasing do not apply oil to cleaning of the obgonny coupling!

Brush holder and brushes


1. Measure the residual length of coal brushes, - if the result of measurement makes less than 11.5 mm (nominal rate = 17.0 mm), brushes are subject to replacement.

2. By means of an ohmmeter measure resistance of isolation of the brush holder. If the result of measurement makes less than 10 megohms, replace the holder.

3. Check freedoms of the course of brushes in directing the holder.

Traction relay


 The checks described below have to be made at strictly stipulated tension! Duration of each check should not exceed 5 seconds!

Make sure available conductivity between S and M plugs, and also between the S plug and weight. Make sure of lack of conductivity between M and B plugs.

Performance data of a starter


1. For ensuring the guaranteed start of the engine in any weather conditions the starter needs to develop high turns of rotation and rather big torque. The listed characteristics to a great extent depend on the battery charge level in view of what check of a starter has to be made with use of the battery which is completely meeting for the performance data the requirements of Specifications.

2. Check of a starter is made in three modes (see further). The scheme of connection of measuring devices is shown on an illustration.

A — the Variable resistor
B — the Traction relay
With — the starter Case

Test without loading


Connect the serviceable battery to the starter disconnected from the engine and measure the rotation frequency, tension and current of a starter. Compare results of measurements to requirements of Specifications.

Test under loading (the recommended method)


During this test check of the torque developed by a starter is made. Check is made at the special test bench, the equipped adaptation for applying of brake effort. Compare results of measurement to requirements of Specifications.

Test under loading with applying of the brake moment (an alternative method)


 Low frequency of rotation, or excessive current can be a consequence of the increased coefficient of internal friction of a starter as a result of the wrong assembly of its components.

Check is made on the same, as earlier test bench in which the anchor of starterny assembly is blocked this time. During check measurement of control parameters is performed, - compare results of measurements to requirements of Specifications.