Starter, Assemble (Valeo)
Press bearing bushing (1) flush into starter housing with suitable drift (2) (see illus. I).
After pressing in bearing bushing, secure with two centre-punch marks on outer side of starter housing.
Lightly lubricate armature shaft and spiral spline with lubricating grease (brown) and position freewheel (3) and friction washer (4) onto the armature shaft. Fit snap ring (5) into groove (6) on armature shaft (see illus. II).
Engage thrust washer in snap ring with remover tool (see illus. III).
Lightly lubricate connecting bar (3) of the starter switch with lubricating grease (brown). Insert engaging lever (2) into sleeve (1) on freewheel and insert connecting bar into opening for starter switch. Fit engaging lever axle (see illus. I).
Place starter switch with spring on tension rod and bolt starter switch to starter (see illus. II).
Lubricate bearing bushing (4) with lubricating grease (brown). Position engaging housing onto starter motor and bolt on (see illus. III).
Place seal (1) on carbon brush holder (2) and place these together on retaining pins on starter (see illus. I).
Place positive carbon brush (3) in carbon brush holder. Insert angled piece (4) of connection strand in seal guide. Place battery lug on connection of starter switch (see illus. II).
Insert negative carbon brush (5) in carbon brush holder. Place battery lug of negative carbon brush on left retaining pin (6) (see illus. III).
Place insulating plates (1) on carbon brushes. Insert spring (2) as shown in illustration and engage in carbon brush holder by pressing firmly on spirals (see illus. I).
Place insulation (3) for housing cover in housing cover and install cover on starter (see illus. II).
Fasten positive carbon brush battery lug (4) to starter switch.
Push insulating sleeve (5) onto positive carbon brush connection until it engages (see illus. III).
Check function of starter on test stand or when installed - see operation "Installed Starter, Check".