1. Front body
2. Retaining ring
3. Emphasis
4. Freewheel
5. Internal gear
6. Lever
7. Lever seal
8. Magnetic switch
9. Planetary gear shaft
10. Planet gear
11. Seal
12. Lid
13. Anchor
14. Body
15. Brush holder
16. Rear housing
17. Coupling bolt
Replacement
1. Disconnect the negative cable from the battery.
2. Disconnect the wire (A) starter from terminal «IN» (IN) electromagnet (WITH), and then connector (D) from withdrawal «S» (E).
3. Turn away two bolts of fastening of a starter, then remove a starter.
Note: Tightening torque: 42.2 - 53.9 Nm.
4. Installation is made in an order, the return to removal.
Disassembly and assembly
1. Disconnect the terminal «M» (A) from magnetic switch (IN).
2. Loosen the three screws (A), then disconnect the magnetic switch (IN).
3. Loosen the tie bolts (A).
4. Remove the brush holder (A), frame (IN) and anchor (WITH).
5. Remove seal (A) and cover (IN).
6. Remove the plate (A) and seal (IN) lever.
7. Remove the planetary gears (A).
8. Disconnect the planetary gear shaft (A) assembly and lever (IN).
9. Press the circlip (A) using a mandrel (IN).
10. Remove retaining ring (A) using a special tool (IN).
11. Remove the stop (A), overrunning clutch (B), internal gear (C) and shaft (D).
12. Assembly is made in the reverse order of disassembly.
Note: Using a suitable puller (A), install retaining ring (IN) overrunning clutch (WITH).
Checking the technical condition
Anchor
1. Remove the starter.
2. Disassemble the starter (see above).
3. Inspect the armature for wear and damage due to permanent magnet contact. If signs of wear or damage are found, replace the anchor with a new one.
4. Inspect the surface of the switch (A). If the surface is dirty or burnt, sand it down with sandpaper or machine it to the size below or polish it with sandpaper (IN) No. 500 or No. 600.
5. Check commutator diameter. If the diameter is less than the limit, replace the anchor with a new one.
Note:
Switch Diameter:
Petrol engines:
- Standard value: 27.1mm.
- Limit value: 26.9 mm.
Diesel engines:
- Standard value: 33.0 mm.
- Limit value: 27.1 mm.
6. Measure switch runout (A). If the commutator runout is within the limit, check the commutator for coal dust and brass chips between the plates. If the commutator runout is out of tolerance, replace the armature with a new one.
Note:
Switch beat:
- Standard value: 0.05 mm.
- Limit value: 0.08 mm.
7. Check the depth of the grooves (A) between the switch plates. If the slot height is too high (IN), cut it to the required depth with a hacksaw blade. All grooves must be cut (WITH) between switch segments. Slots should not be too thin, concave or V-shaped (D).
Note:
Groove depth:
Petrol engines:
- Standard value: 0.8 mm.
- Limit value: 0.2 mm.
Diesel engines:
- Standard value: 0.5 mm.
- Limit value: 0.2 mm.
8. Check the electrical conductivity between the commutator plates. If there is a broken chain between any of the plates, replace the armature with a new one.
9. Use an ohmmeter to verify that there is no electrical continuity between the switch (A) and armature coil core (IN), as well as between the commutator and the armature shaft (WITH). If there is electrical conductivity, replace the armature with a new one.
Starter brushes
10. Worn or oily brushes must be replaced with new ones.
Starter brush holder
11. Check for continuity between the brush holder (+) (A) and plate (-) (IN). If there is conductivity, replace the brush holder with a new one.
12. Compress the spring (A) each brush with a screwdriver, then position the brush (IN) so that it protrudes halfway out of the holder. Release the spring to hold the brush.
13.Install the anchor into the housing, then install the brush holder. Compress the spring of each brush again and lower the brush to set it against the commutator. Release the spring towards the edge of the brush.
Note: To install new brushes, place #500 or #600 sandpaper between the commutator and each brush, grit side up, and gently rotate the armature. The contact surface of the brushes will be ground to the contour of the commutator.
Freewheel
14. Move the freewheel along the shaft. If the clutch does not move smoothly, replace it with a new one.
15. Try turning the freewheel in both directions. If the clutch does not lock in one direction, or if it locks in both directions, replace it with a new one.
16. If the drive gear is worn or damaged, replace the freewheel (gear is not available as a separate spare part). If the starter drive gear teeth are damaged, check the condition of the flywheel and torque converter ring gear.
Cleaning
1. Do not immerse parts in cleaning solvent. Immersion in armature solvent will damage the wiring insulation. These parts may only be wiped with a cloth.
2. Do not immerse the freewheel in cleaning solvent. It has factory grease.
3. The drive may be cleaned with a brush soaked in a cleaning solution, after which the drive must be wiped dry with a cloth.