Disassembling the starter 1.4, 2.0 and 2.2 kW (ZS-T)
1. Loosen the screw, remove the spring washer, bolt and wire lead.
2. Remove the stator and anchor.
a) Unscrew the nut and disconnect the wire terminal from the traction relay terminal.
b) Unscrew the two tie bolts and remove the stator together with the anchor.
c) Remove the sealing ring from the stator.
Starter 1.4 and 2.0 kW
Starter 2.2 kW
3. Remove the starter housing, overrunning clutch assembly and gear.
a) Unscrew the two bolts.
b) Remove the following parts from the traction relay.
(Starter 1.4 and 2.0 kW)
- (1) Starter cover on the drive side;
- (2) return spring;
- (3) bearing;
- (4) intermediate gear;
- (5) overrunning clutch assembly.
(Starter 2.2 kW)
- (1) Starter cover on the drive side;
- (2) return spring;
- (3) drive gear;
- (4) bearing;
- (5) intermediate gear;
- (6) overrunning clutch assembly.
Disassembly and assembly of a 2.2 kW starter (ZS-T).
1 - starter housing (stator),
2 - O-ring seal,
3 - front bearing,
4 - anchor,
5 - rear bearing,
6 - brush holder,
7 - overrunning clutch assembly,
8 - steel ball,
9 - return spring,
10 - traction relay,
11 - anther,
12 - wiring output,
13 - bearing,
14 - intermediate gear,
15 - drive gear,
16 - starter cover on the drive side.
Disassembly and assembly of a 1.4 kW starter (ZS-T).
1 - end cap,
2 - sealing ring,
3 - brush holder,
4 - stator,
5 - front bearing,
6 - anchor,
7 - rear bearing,
8 - overrunning clutch assembly,
9 - steel ball,
10 - return spring,
11 - traction relay,
12 - anther,
13 - wire output,
14 - bearing,
15 - intermediate gear,
16 - starter housing.
4. Using a magnetic rod, remove the steel ball from the hole in the overrunning clutch shaft.
Disassembly and assembly of a 2.0 kW starter (ZS-T).
1 - traction relay,
2 - return spring,
3 - steel ball,
4 - overrunning clutch assembly,
5 - bolt,
6 - starter cover on the drive side,
7-, 8 - bearing,
9 - intermediate gear,
10 - drive gear,
11 - wire output,
12 - brush holder,
13 - spring,
14-, 18 - sealing ring,
19 - housing assembled with stator winding,
20-, 21 - bearing.
5. Remove the brush holder.
a) (Starter 1.4 and 2.0 kW) Remove the two screws, remove the two O-rings and the end cover from the stator, and then remove the O-ring from the stator.
b) Using a screwdriver, press the spring and detach the brush from the brush holder. Detach the four brushes and remove the brush holder.
Starter 1.4 and 2.0 kW
Starter 2.2 kW
6. Remove the anchor from the stator.
Starter 1.4 and 2.0 kW.
Starter 2.2 kW.
Assembly of starter 1.4, 2.0 and 2.2 kW (ZS-T)
Note: Use high temperature grease to treat the bearings and gears when assembling the starter.
1. Install the armature into the stator.
Apply grease to the armature bearings and insert the armature into the stator.
2. Install the brush holder
a) (Starter 2.0 and 2.2 kW) Align the brush holder protrusion with the groove in the starter housing.
b) Install the brush holder on the anchor.
c) Using a screwdriver, press the brush springs. Install four brushes.
Note: Make sure that the positive terminals of the wires are not grounded.
g) (Starter 1.4 kW) Install a new O-ring onto the stator.
d) (Starter 1.4 and 2.0 kW) Install a new O-ring onto the screw.
e) (Starter 1.4 and 2.0 kW) Install the cover on the manifold side and secure it with two screws.
3. Insert a steel ball into the hole of the overrunning clutch shaft.
Apply grease to the ball and insert it into the shaft hole.
4. Install the starter drive side cover, overrunning clutch assembly and gears.
a) Apply grease to the return spring.
b) Insert the return spring into the hole of the traction relay.
c) Install the following parts into the drive side cover:
(Starter 1.4 kW)
- (1) overrunning clutch assembly;
- (2) intermediate gear;
- (3) bearing.
(Starter 2.0 and 2.2 kW)
- (1) overrunning clutch assembly;
- (2) intermediate gear;
- (3) bearing;
- (4) drive gear.
d) Install the starter housing and secure it with two screws.
5. Install the armature and stator.
a) Install a new sealing ring onto the stator.
Starter 1.4 kW
Starter 2.2 kW
b) (Starter 1.4 kW) Align the protrusion on the stator with the groove on the traction relay.
v) (Starter 2.2 kW) Align the brush holder tabs with the slots on the traction relay housing and install the starter housing and armature shaft assembly.
g) (Starter 2.0 and 2.2 kW) Align the stamped mark (reference point) on the starter housing with the mark on the traction relay housing.
d) (Starter 2.2 kW) Install a new O-ring onto the tie rod.
e) Install the stator and armature and secure them with two tie bolts.
g) Connect the wire lead to terminal C and secure it with a nut.
6. Install the wire terminal Install the wire terminal and secure it with the bolt, spring washer and screw.