Starter, Assemble
Press in ball bearing on commutator side to stop on armature shaft using suitable assembly sleeve.
Closed side of ball bearing faces commutator.
Press in ball bearing on winding side to stop on armature shaft using suitable assembly sleeve.
Closed side of ball bearing faces winding.
Place spacer ring and spacer washer in overrunning clutch hollow shaft and press on ball bearing to stop with suitable assembly sleeve (see illus. I).
Press reduction gear with spacer ring onto hollow shaft by hand.
Install reduction gear with collar (1) on top.
Press on small bearing to stop on overrunning clutch hollow shaft using suitable assembly sleeve (see illus. III).
Coat edge of starter frame (1) with sealing compound and place new O-ring on starter frame.
Insert armature in starter frame.
Place carbon brush holder on starter frame.
Locking lug (2) must engage in groove on starter frame.
Insert carbon brushes.
Insert springs into guides.
Using screwdriver or other suitable tool, place spring on carbon brush (3).
Place shim on starter switch.
Insert piston and press torsion spring into special bores on starter switch (see illus. I).
Insert starter lever in starter housing with groove on top and press in rubber support by hand up to stop on both sides (see illus. II).
Coat engaging housing wall and rear bolt contact face (see illus. III, arrows) with surface sealant (green) before installing the starter switch.
Attach starter switch in starter lever above torsion spring and piston eyelet.
Bolt starter switch to starter housing (see illus. I).
Starter switch to starter housing - 7.5 Nm / 5.5 lbf. ft.
Screw pinion gear shaft into overrunning clutch.
Attach return spring and retaining ring. Compress return spring via retaining ring with suitable open-ended wrench and lock new snap ring on shaft (see illus. II).
Freewheel must lock when the starter pinion is turned in the drive direction. (1)
Starter pinion must turn easily against drive direction (2)
Lubricate overrunning clutch reduction gear with bearing grease and insert in housing.
Lay bearing bracket ring straight on the bearing and press on by hand.
Tighten fastening bolts.
Insert pre-assembled starter motor into the engaging housing, position rear housing cover and tighten through bolts.
Starter motor to starter housing - 6.5 Nm / 5 lbf. ft.
Bolt field winding connection to starter switch - 9 Nm / 7 lbf. ft.
After overhauling starter, check starter pinion end play.
Remove starter pinion by hand and measure distance from pinion gear to flange (see illus.)
Connect starter frame to battery negative terminal using auxiliary cable. Using second auxiliary cable, actuate starter switch via terminal 50.
Do not actuate starter switch for longer than 30 seconds.
Measure distance from ejected pinion gear to flange.
The difference between the first and second measurements must be 0.3 - 1.5 mm/0.012 - 0.059 in.
If the value is not reached or exceeded, adjust axial play by adding appropriate spacer washers. For this, remove starter switch - see operations "Starter, Disassemble" and "Starter, Assemble" in this group.