Starter

The starter on the right side of the engine is difficult to access (the illustration shows a 4-cylinder engine)
1 – starter motor;
2 – terminal 50 lead (from ignition switch);
3 – terminal 30 lead (from battery);
4 – starter motor mounting.

The illustration shows the starter motor (5-cylinder engine) disassembled
1 – brush holder;
2 – armature;
3 – reduction gear;
4 – engagement housing bearing;
5 – housing
6 – bearing housing cover;
7 – bearing cover;
8 – stop washer, adjusting washer and gasket.

Starting the Engine
PROCEDURE

When the ignition key is turned to the "Start" position, power is supplied to terminal 50 of the solenoid switch located on top of the starter motor.

At the same time the actuating lever engages the starter pinion with the flywheel ring gear along the helical splines.

Only after the pinion is fully engaged does the solenoid switch connect full battery power from terminal 30, and the starter then cranks the engine vigorously.

The starter motor and pinion are connected through a reduction gear. Therefore the electric motor rotates considerably faster than the pinion.

Once the engine has started, the pinion disengages from the flywheel again.

Removing the Starter Motor
PROCEDURE

Disconnect the earth lead from the battery, otherwise there is a high risk of a short circuit.

Remove the engine compartment undershield (refer to Body Components).

Raise the vehicle at the front right and secure it.

Disconnect all wires from the solenoid switch.

Remove the starter bracket at the front in the direction of travel (where fitted).

Unscrew the mounting bolts or nuts on the starter mounting flange (i.e. at the rear in the direction of travel).

Remove the starter motor.

Brush replacement
If the starter does not work, the cause may be worn brushes. Carbon brushes are only available together with the brush holder plate. Since the starter housing must be sealed after opening, you will also need sealant D 3 from the parts store. Then, for models with a 4-cylinder engine, a powerful soldering iron and solder are required.

PROCEDURE

Remove the starter motor.

On the closed side of the starter, unscrew the two slotted-head screws securing the small bearing cover, and remove the cover.

Remove the lock washer and the adjusting washer from the shaft located under the cover.

Remove both screws (or nuts from the studs) from the rear housing cover and remove the cover.

Measure the length of the brushes – minimum length 8 mm.

To replace the brushes, disconnect the brush holder plate from the solenoid switch.

Reassemble the starter, sealing the housing cover, the mounting screws and the bearing cover.

Removing the solenoid switch
PROCEDURE

Remove the starter motor.

Disconnect the wire from the starter motor.

Unscrew the three screws on the solenoid switch mounting flange.

Gently press the solenoid switch aside and remove the lug from the starter lever.