Note: Depending on the malfunction that has occurred, the sequence and scope of repair work may be changed.
The most frequently occurring faults:
1. The winding burns out or the contact bolts and contact plate burn in the traction relay. To eliminate these faults, it is necessary to replace the traction relay. This can be done on the car without removing the starter.
2. The drive overrunning clutch is faulty. To eliminate this fault, it is necessary to disassemble the starter and replace the drive.
3. The starter brushes are worn out. The starter should be removed, the brush assembly replaced, and the commutator cleaned. When replacing the brush assembly, there is no need to remove the starter drive and traction relay.
To complete the work you will need:
- two power wires (with clamps on the ends) to start the engine from the battery of another car;
- release tongs for removing locking rings;
- ohmmeter.
Examination
Note: You can check the electrical part of the starter without disassembling it
1. Remove the starter (see "Starter - removal and installation").
(The original is posted on Internet resource VAZbook.ru)
Warning! When checking, do not short-circuit the clamp of the wire connected to the positive terminal of the battery to the starter housing. To do this, extend the clamp, for example, by inserting a steel punch into it.
2. Using one wire, connect the negative terminal of the battery to the starter housing. The second wire, connected to the positive terminal of the battery, is connected to the contact bolt (2) of the traction relay, to which the starter wire is connected. If the starter anchor begins to rotate, the starter motor is in good condition.
3. Connect the second wire to the contact bolt (1) of the traction relay. Using a screwdriver or other suitable metal object, close the terminal (3) and the contact bolt of the traction relay. If a loud click is heard and the starter armature begins to rotate, the traction relay is working properly.
To further check the starter, as well as to determine the cause of the malfunction, it is necessary to disassemble the starter.
Disassembly
1. With a socket wrench by 10 mm unscrew the nut securing the wire tip to the terminal (contact bolt) traction relay.
2. Remove the wire tip from the contact bolt of the traction relay.
3. With a socket wrench by 8 mm we unscrew the two bolts securing the traction relay.
4. Remove the traction relay from the starter (in this case it is necessary to disconnect the relay core earring from the upper end of the drive lever).
Recommendation. Check the ease of movement of the traction relay core. Connect an ohmmeter to the terminals of the traction relay and, by pressing the anchor to the stop, make sure that the contact bolts close (electrical resistance is close to zero). The faulty traction relay must be replaced.
5. With a socket wrench by 10 mm we unscrew the two nuts of the tie rods.
6. Carefully disconnect the stator from the front cover and remove the stator assembly with the anchor from the studs.
7. Remove the central gear of the planetary gearbox (sometimes the gear remains on the armature shaft).
8. Using a slotted screwdriver, remove the three planetary gears of the gearbox one by one.
Recommendation. Check the condition of the planetary gearbox. The needle bearings of the satellite gears should not be damaged. There should be no chips, burrs, traces of corrosion or other damage on the gearbox teeth. It is necessary to replace the faulty gearbox elements (either the drive or the starter assembly).
9. Using a screwdriver, press against the top of the front cover of the starter and pry up the drive lever support.
10. Remove the drive from the cover together with the drive shaft, drive lever, lever support and external gear of the gearbox.
Recommendation. Check the condition of the drive. The drive should move freely along the shaft splines without jamming. The drive gear should be screwed on freely in one direction only, chipped teeth and strong nicks on the lead-in part of the teeth are unacceptable. Minor defects can be eliminated with a diamond file or an abrasive stone. It is necessary to replace a faulty and heavily worn drive (or starter assembly).
11. With a hammer through an open-end wrench by 13 mm knock down the starter drive travel limiter ring (in this case, a wooden block or a piece of thick rubber should be placed under the gearbox gear).
12. Using a slotted screwdriver, remove the drive travel limiter retaining ring from the groove in the shaft and remove the retaining ring and travel limiter ring from the shaft.
13. Remove the drive assembly with the lever and clutch from the shaft.
14. Using special expanding pliers, remove the retaining ring (see photo, item 15, pos. 1) drive lever couplings.
15. Remove the washer (2) and the coupling (5) together with the drive lever (3) from the drive (4).
Note: When replacing only the drive, further work on disassembling the starter can be omitted.
16. Using special expanding pliers, remove the retaining ring (see photo, item 17, pos. 6) drive shaft supports.
17. From the drive shaft (1), sequentially remove the thrust washer (5), shaft support (4), sealing rubber ring (3) and external gear of the planetary gear (2).
18. Using a Phillips screwdriver, unscrew the two screws securing the brush assembly to the rear cover of the starter.
19. Remove the back cover.
20. Using a slotted screwdriver, remove the brush assembly from the armature collector.
21. Remove the front support of the anchor shaft.
22. Remove the thrust washer from the armature shaft.
23. Overcoming the force of the magnets, we remove the anchor from the stator.
24. Inspect the commutator and armature windings.
Note: Traces of charring of windings are not allowed - such anchor must be replaced.
25. Clean the dirty commutator with sandpaper ("zero"), clamping the anchor shaft through a strip of thick paper in the chuck of an electric drill. Wash the anchor with water and detergent to remove dirt, coal dust and abrasive residues and carefully wipe dry with a clean rag, blow with compressed air from a tire pump.
26. Replace worn brushes (the height from the working edge to the outlet is equal to or less than 3.5 mm) and brushes that have mechanical damage.
27. Wash the gearbox and drive parts with white spirit or kerosene.
Assembly
The brush assembly can be installed on the starter armature collector using a special mandrel or tool head of the appropriate size and shape. If they are not available, the brushes can be installed without these devices. To do this:
1. Using two screws, attach the brush assembly to the rear cover of the starter.
2. Lubricate the end of the anchor shaft with two drops of motor oil.
3. Insert four brushes into the corresponding brush holders. Without inserting the brush springs into the brush holders, place the brush assembly on the armature collector.
4. Using thin-nosed pliers, bend back the outer spring stops of all four brushes.
5. Insert the spring into the brush holder.
6. Holding the spring with a screwdriver, bend the four spring stops with pliers. Install the remaining three springs in the same way.
7. Insert the starter anchor into the stator with the brush assembly and rear cover placed on it (in this case, it is necessary to hold the anchor so that its collector does not come out of engagement with the brush assembly).
Further assembly of the starter is performed in the reverse order of disassembly. In this case, apply plastic grease to the gearbox parts. Before installing the drive, dip it in engine oil and let the oil drain. Lubricate the drive screw splines, as well as the bushings in which the anchor and drive shafts rotate, with engine oil.
8. To ensure that the starter is assembled correctly, before installation, check its functionality, as shown at the beginning of the section.