Assemble
Solenoid switch adjusting shims plunger torsion spring engaging lever and dust cover to pinion case - coat sliding sufaces of engaging lever and plunger with Grease 91 001 812/19 41 574; bolt 7 Nm.
Assemble
Clutch (4) pinion shaft (3) spring (2) stopper (1) and circlip - coat pinion shaft and reduction gear with Grease 91 001 812/19 41 574.
Pinion assembly and bearing retainer to pinion case.
Assemble
Armature stator and brush holder - raise springs to fit brushes onto commutator.
Caution
Do no damage surface of commutator.
Assemble
Through bolts - 6 Nm; rear cover – two screws.
Cable to terminal M of solenoid switch – nut 9 Nm.
Measure
End play of engaged pinion.
Connect terminal S to battery positive terminal and terminal M to battery negative rerminal - use auxiliary cables.
Switch on measure dimension from pinion to pinion case pull pinion manually in direction of arrow then remeasure dimension - use vernier caliper.
Caution
Do not energize solenoid switch for more than 30 seconds.
Difference A between two dimensions is end play of engaged pinion and must be 0.3-1.5 mm.
Adjust
End play of engaged pinion by changing shim(s) (arrowed).
