Starter disassembly 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 armature.
A) Turn away a nut, and disconnect an output of a wire from an output of the traction relay.
b) Unscrew the two coupling bolts and remove the stator together with the armature.
V) Remove the o-ring from the stator.
Starter 1.4 and 2.0 kW
Starter 2.2 kW
3. Remove the starter housing, freewheel assembly and gear.
A) Remove two bolts.
b) Remove the following parts from the traction relay.
(Starter 1.4 and 2.0 kW)
- (1) drive side starter cover;
- (2) return spring;
- (3) bearing;
- (4) intermediate gear;
- (5) overrunning clutch assembly.
(Starter 2.2 kW)
- (1) drive side starter cover;
- (2) return spring;
- (3) drive gear;
- (4) bearing;
- (5) intermediate gear;
- (6) overrunning clutch assembly.
Disassembly and assembly of the starter 2.2 kW (ZS-T).
1 - starter housing (stator),
2 - 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 the starter 1.4 kW (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 freewheel shaft.
Disassembly and assembly of the starter 2.0 kW (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 complete with stator winding,
20-, 21 - bearing.
5. Remove the brush holder.
A) (Starter 1.4 and 2.0 kW) Loosen the two screws, remove the two O-rings and the end cap from the stator, and then remove the O-ring from the stator.
b) Using a screwdriver, depress the spring and disconnect the brush from the brush holder. Disconnect the four brushes and remove the brush holder.
Starter 1.4 and 2.0 kW
Starter 2.2 kW
6. Remove the armature from the stator.
Starter 1.4 and 2.0 kW.
Starter 2.2 kW.
Starter assembly 1.4, 2.0 and 2.2 kW (ZS-T)
Note: Use high temperature grease to treat bearings and gears when assembling the starter.
1. Install the armature in 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 protrusion of the brush holder with the groove in the starter housing.
b) Install the brush holder on the anchor.
V) Use a screwdriver to pry out the brush springs. Install four brushes.
Note: Check that the positive leads of the wires are not grounded.
G) (Starter 1.4 kW) Install a new O-ring on the stator.
d) (Starter 1.4 and 2.0 kW) Install a new O-ring on the screw.
e) (Starter 1.4 and 2.0 kW) Install the manifold side cover and secure it with two screws.
3. Insert a steel ball into the freewheel shaft bore.
Apply grease to the ball and insert it into the shaft hole.
4. Install drive side starter cover, freewheel assembly and gears.
A) Apply grease to the return spring.
b) Insert the return spring into the opening of the traction relay.
V) Install the following parts in 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.
G) Install the starter housing and secure it with two screws.
5. Install armature and stator.
A) Install a new O-ring on 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 protrusions of the brush holder with the grooves on the traction relay housing and install the starter housing and armature shaft assembly.
G) (Starter 2.0 and 2.2 kW) Align the embossed mark (benchmark) on the starter housing with a label on the traction relay housing.
d) (Starter 2.2 kW) Install a new O-ring on the pinch bolt.
e) Install the stator and armature and secure them with two tie bolts.
and) Connect the wire lead to terminal C and secure it with a nut.
6. Install the wire lead. Install the wire lead and secure it with the bolt, spring washer and screw.