Removal and installation
Removal and installation of a starter in gathering
1. Disconnect a wire from the negative plug of the storage battery.
2. Disconnect the speedometer drive cable and gearshift cable.
3. Disconnect the starter harness connector and starter output wire.
4. Remove the starter assembly.
5. Installation is made in an order, the return to removal.
Disassembly
Starter disassembly.
1 - screw, 2 - restrictive ring, 3 - lever, 4 - plate, 5 - stop, 6 - starter traction relay, 7 - front bracket assembly, 8 - retaining ring, 9 - overrunning clutch, 10 - internal gear, 11 - carrier, 12 - satellite, 13 - ball, 14 - sealing ring, 15 - coupling bolt, 16 - pole with stator winding assembly, 17 - starter armature, 18 - brush holder, 19 - rear bracket, 20 - screw.
To remove the overrunning clutch from the starter armature shaft, it is necessary to remove the retaining and restrictive rings.
- A) Using a suitable drift, slide the stop ring down.
- b) Using special pliers, remove the retaining ring, then remove the stop ring and starter freewheel.
Examination (after disassembly)
Check for the absence of a short circuit in the armature winding "mass"
Using an ohmmeter, check for continuity between each commutator lamella and the armature core. If the circuit is closed (resistance go to zero), replace the starter armature assembly.
Checking for a short circuit in the armature winding
Install the armature in the starter and alternator winding tester). If there are signs of a short circuit, then replace the armature. If a thin steel plate located at the armature body vibrates when the starter armature rotates, then the armature winding is short-circuited.
Checking for an open in the armature winding
Use an ohmmeter to check for a closed circuit (resistance) between the collector lamellas. If the circuit is open, then there is an open in the armature winding.
Check for continuity in the stator winding
Use an ohmmeter to check for continuity between the brush wires. If the circuit is open, then there is an open in the stator winding. In this case, replace the starter housing assembly with the stator winding.
Check for the absence of a short circuit in the stator winding "mass"
With the winding installed on the stator, check the absence of a closed circuit between the brush output (stator winding) and starter housing using an ohmmeter. If the circuit is closed, then replace the starter housing assembly with the stator winding.
Manifold check
1. Place the starter armature on two V-blocks and measure the radial runout of the manifold with a dial gauge.
- Rated value: 0.05mm
- Limit value: 0.10 mm
2. Measure the outside diameter of the manifold.
- Rated value: 29.4 mm
- Limit value: 28.4 mm
3. Check the protrusion of the collector lamellas above the insulator.
- Rated value: 0.5mm
- Limit value: 0.20 mm
Checking the brush holder
Check for an open circuit between the plate (a plus) brush holder and brush holder. If the circuit is shorted, replace the brush holder assembly.
Brush check
1. Brushes worn below the wear limit or oily should be replaced.
2. To replace the brushes, be careful not to damage the wires of the brushes, crush the old brushes with pliers.
Overrunning clutch test
1. Rotate the drive gear while holding the freewheel housing. The gear should rotate smoothly, without jamming, in one direction, and not rotate in the opposite direction.
2. Check up a condition of teeths of a leading gear wheel of a starter. If there is wear, scoring, or chipped teeth, replace the overrunning clutch assembly. If the drive gear is damaged, check the condition of the flywheel ring gear (models with manual transmission) or torque converter (models with automatic transmission) for scoring or excessive wear.
Brush replacement
1. Remove the worn brush, being careful not to damage the brush wire.
2. Sand the end of the brush wire with sandpaper to ensure a strong solder.
3. Insert the conductor into the hole of the new brush and solder it. At the same time, make sure that the end of the conductor and excess solder do not protrude beyond the surface of the brush.
4. When replacing the negative brush, pull the brush out of the brush holder by pulling back on the retaining spring.
Replacing the bushing of the front and rear brackets
Check bushings for excessive wear or nicks. If defects are found, replace the front or rear starter bracket assembly.
Assembly
1. Install a freewheel onto the front end of the starter armature shaft.
2. Install the stop ring first, then the circlip on the front end of the starter armature shaft. Slide the freewheel stop ring onto the circlip until it stops.