1. Remove the starter from the car (see «Removal and installation of a starter»).
2. Remove the nut from the bottom contact bolt.
3. Remove the washer and disconnect the stator winding lead.
4. Turn away two screws of fastening of the traction relay.
5. Remove the traction relay. To do this, disconnect the relay armature from the lever by lifting the relay.
6. Take out an anchor and a spring from the traction relay.
7. Remove the O-ring.
8. Using a tube of suitable diameter, knock the stop ring off the retainer ring.
Note. The restrictive ring is fixed with a retaining ring installed under it.
9. Remove the retaining ring, and then restrictive.
10. Turn out two screws of fastening and remove a protective cover.
11. Remove the circlip..
12.... and then shims.
13. Loosen the tie rod nuts..
14.... and remove the cover from the collector side.
15. Depress the springs of both insulated brushes with a screwdriver and remove the brushes from the brush holder.
16. Remove the brush holder.
Note. Insulated brushes 1 are soldered to the terminals of the stator windings, and uninsulated brushes 2 are soldered to the brush holder. When the brush holder is removed, the insulated brushes remain on the stator winding terminals.
17. Remove the housing with the stator.
Note. Four excitation windings are fixed in the starter housing.
18. Remove the plastic lever stop.
19. Remove the anchor from the cover on the drive side.
20. Remove the intermediate support from the armature shaft.
21. Remove the circlip from the starter drive.
Note. This is how the details of the starter drive look like: 1 - gear; 2 – drive lever; 3 - overrunning clutch; 4 - disc washer.
22. Remove the Belleville Washer..
23.... thrust washer..
24.... a clutch with a lever..
25.... and a thrust ring.
26. Turn out two screws of fastening of a cover of the traction relay.
Warning! Disassemble the traction relay only if it is necessary to repair it.
27. Turn away nuts from two contact bolts of the traction relay.
28. Disconnect both leads of the windings from the leads of the traction relay with a soldering iron.
29. Remove the cover of the traction relay.
30. Remove the o-ring.
31. Remove the contact plate assembly with the stem.
32. Remove the return spring from the stem..
33.... retaining ring..
34.... and an insulating washer.
35. Remove the contact plate..
Note. Contact plate fixing details (shown in order of installation on the stem).
36.... insulating sleeve..
37.... the puck..
38.... and a damping spring.
39. Remove the contact bolts from the cover.
Note. The windings of the traction relay are installed in a non-separable case, therefore, if they are damaged, replace the traction relay assembly.
40. Clear all details of a starter of pollution.
41. Check the condition of the stator winding. To do this, turn on the test lamp in an alternating current circuit with a voltage of 220 V and connect the wire to one of the stator winding terminals, close the other end of the circuit to the housing. If the lamp is on, then the winding insulation is damaged. Replace winding or stator. Check the second winding in the same way.
Warning! When checking with a voltage of 220 V, be careful not to touch parts of the starter that are energized with your hands.
Helpful advice. The stator windings can be checked with a megger. Connect one contact to the output, the other to the stator housing. Winding resistance must be at least 10 kOhm. If it is less, replace the stator.
42. Examine the anchor. If the collector is dirty or has marks or scratches on it, sand it with fine glass sandpaper. With a significant roughness of the collector or when mica protrudes between the plates, machine the collector on a lathe and then grind with fine glass sandpaper. The runout of the core relative to the pins of the shaft should not exceed 0.08 mm. If the runout is greater, replace the anchor.
43. If there is yellow coating from the bearing on the armature shaft, remove it with fine sandpaper, otherwise this will cause the gear to seize on the shaft.
If scuffs, nicks appear on the surfaces of the pins and splines of the shaft, replace the anchor.
44. Check the reliability of the soldering of the armature winding leads to the collector plates. Inspect the winding at the ends of the armature: the diameter of the winding should be less than the iron package of the armature. If the diameter is larger, replace the anchor.
45. Check the condition of the armature winding with a test lamp in the 220 V AC circuit. Connect the wires to the collector plate and the armature core. If the lamp lights up, then there is a short circuit in the armature winding or collector plate on «mass». In this case, the anchor must be replaced.
Helpful advice. Armature windings can be checked with a megger. Connect one of its contacts to the collector, the other to the armature core. Winding resistance must be at least 10 kOhm. If there is less resistance, replace the armature.
46. While holding the freewheel, try turning the starter gear in both directions: it should rotate freely in a clockwise direction only. If the gear rotates in both directions, replace the drive.
47. Put the starter drive on the armature shaft. It should move freely, without jamming, along the splines of the shaft.
48. If drive parts are badly worn or damaged, replace drive. If nicks are found on the engagement part of the gear teeth, grind them with a fine-grained emery wheel of small diameter.
49. Examine a cover of a starter from a collector and an intermediate support. If cracks appear on these parts, replace them. Also inspect the bushings in the cover and support in which the armature shaft rotates. If severe wear or mechanical damage is found, replace the cover or support with defective bushings.
50. Inspect the sleeve pressed into the clutch housing. If the bushing is worn or burrs, shells appear on it, replace the bushing.
Helpful advice. The sleeve is located in a blind hole in the clutch housing and is therefore difficult to access. To remove the bushing, wrap a tap of a suitable size into it until it stops at the bottom of the hole, as if cutting a thread in the bushing. With further rotation of the tap, the sleeve will be pressed out of the hole.
51. Brushes worn to a height of less than 12 mm must be replaced.
52. Check the movement of the brushes in the holders. The brushes should move easily, without jamming. Check the fastening of the brush holders: they must be firmly fixed.
53. Holders of insulated brushes should not be shorted to «mass». Check this with a test lamp.
54. Check up force of the springs pressing brushes, by means of a dynamometer. To do this, insert the anchor into the cover on the drive side, install the housing and brush holder.
55. Insert the brushes into the brush holders. At the moment of separation of the spring from the brush, the force should be in the range of 9.0–11.0 N (0.9–1.1 kgf).
56. Check the resistance of the windings of the traction relay with an ohmmeter. The resistance of the retracting winding should be in the range of 0.52–0.59 ohms (dashed red lines), and holding - 0.725–0.795 Ohm (solid yellow lines) at ambient temperature from +15 to +25°С. The armature of the traction relay must move freely in the housing, without jamming.
Note. Simultaneously with checking the resistance of the winding, check whether the contact plate closes the contact bolts of the traction relay. If the ohmmeter shows infinity, then either a break has occurred in the winding, or the plate does not close the contact bolts. In the first case, the traction relay must be replaced.
57. Inspect the contact bolts. Clean the burnt heads of the bolts with a fine sandpaper. In case of severe burnout of the heads, you can turn the bolts by 180°so that they are pressed against the contact plate with the unburned side. If the surface of the contact plate is heavily worn, then it can be turned to the other side of the contact bolts.
When assembling the starter, do the following.
1. Securely solder the winding leads to the contacts of the traction relay.
2. Lubricate the splines and trunnions of the armature shaft with engine oil..
3.... bushings of the rear cover and intermediate support..
4.... armature tip of the traction relay..
5.... and freewheel splines.
6. By selecting shims, adjust the axial clearance of the starter armature shaft. The gap should be no more than 0.5 mm.
7. Install the support on the lever with the protrusion towards the anchor.
8. The tie rods must pass through the conduits.
9. When connecting the lever to the tip of the armature of the traction relay, the tongue on the tip of the anchor must be directed downwards.