1. Remove the starter from the car (see «Removal and installation of a starter»).
2. Turn away a nut of fastening of the lower contact bolt..
3.... remove the washer and disconnect the tip of the stator winding output.
4. Turn out two bolts of fastening of the traction relay to the case..
5.... remove the relay..
6.... and remove the anchor of the traction relay from the drive lever.
7. Remove a sealing lining of the traction relay.
8. Overcoming the resistance of the retaining ring, slide the limit ring of the drive gear along the shaft
9. Remove the retainer from the drive shaft..
10.... and restrictive rings.
11. Unscrew the two nuts of the tie rods..
12.... and remove the back cover with the brush holder.
13. Pry out the fixing bracket of the brushes..
14.... remove the bracket..
15.... brush spring..
16.... and a brush.
17. Remove the two screws securing the brush holder to the cover..
18.... and remove the brush holder.
19. Pry off the retainers of the holders of the remaining brushes..
20.... remove the clamps and clamping springs. Replace deformed or damaged retainers and heavily compressed or bent springs.
21. Remove the brushes from the brush holder guides.
22. Remove bare brushes.
23. Remove the cardboard insulating pad. Replace a torn or over-compressed gasket.
24. Remove the connecting bus with insulated brushes.
Notes: Replace brushes that are worn to less than 3.5mm between the wear surface and the lead.
Use a caliper to measure.
25. Remove the starter housing from the cover studs.
26. Remove the central gear from the armature shaft..
27.... and an intermediate support.
Note. A washer is installed on the armature shaft from the drive side.
28. Examine the anchor. If collector 1 is dirty or has marks, signs of burning, etc., sand the collector with fine glass sandpaper. With a significant roughness of the collector or protrusion of mica between its plates (lamellas) machine the manifold 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. Otherwise, replace the anchor. If a coating from a yellow bearing is found on the armature shaft 2, remove the coating with fine sandpaper, as this can lead to gear seizing on the shaft. If there are scuffs or nicks on the surfaces of the pins and splines of the shaft, replace the anchor. Check the reliability of the soldering of the winding leads of the 3rd armature 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. Otherwise, replace the anchor.
29. Check the condition of the armature winding using a test lamp powered by 220 V alternating current. Apply voltage to the collector plate and armature core. The lamp should not light up. If the lamp is on, then there is a short circuit in the armature winding or collector plate on «mass». In this case, replace the anchor.
30. Turn out hairpins from a cover of a starter from outside a drive.
31. Remove the three planetary gears of the drive shaft. If their teeth or needle bearings mounted in the gears are damaged, replace them.
32. Remove the drive shaft with the lever from the cover.
33. Remove the seal.
34. Remove the overrunning clutch assembly with the drive gear from the drive shaft.
35. Remove the circlip..
36.... remote ring..
37.... and a lever.
38. Remove retaining ring, shaft support and sun wheel
Assemble the starter in the reverse order of disassembly, bearing in mind the following.
1. Before assembly, lubricate the teeth of the drive gear with engine oil, grease (CIATIM-201, 202, 203 or Litol-24) drive shaft helical splines, internal gear teeth, planetary gears and rotor shaft splines.
2. The brush holder must be installed in the starter separately from the cover on the collector side, since the brushes are pushed out of the guides by springs and it is impossible to keep them in their original position without a special device. For pre-assembly and installation of the brush holder, use a thin-walled mounting sleeve 1, the diameter of which is equal to the diameter of the collector or slightly larger than it (about 30 mm) …
3.... and install the assembled brush holder into the starter housing until it stops, remove the mounting sleeve and install the cover on the collector side.