Starters 3-29 BOSCH Audi Peugeot TESTING Bmw Porsche Fat Seab Lock Test Mount storter ino test stand to ollow starlet tor- Fiesta Volkswagen ae, measurement low malades isco), Wh cedes-Benz lve ‘oltage adiusted to specifications, ammeter reading and star 7 veh {or torque should be’ within specifications oa Free Running Test With starter in tes bench, take readings of starter current, voltage and RPM. Readings should be within Starter is @ brush type, series wound elecrie motor equipped with on overrunning clutch, Integral solenoid mounted on the sorter engages storter pinion geor with flywheel ring gear When starter is engaged. Field frame is enclosed by com: mutator end frame ond drive bushing and carries pole shows ‘ond field coils, A spline on the drive end ofthe armature shaft s the overrunning clutch ond pinion assembly, Armature is supported in sintered bronze bushings in the com: mutator end frame and drive end housings APPLICATION Model (Bosch Part No. Audi +4000 22718 5000 311 122 +5000 Diesel 362 069 Bmw 3201 311 100 528i, 633¢3i & 7331 314 025 Fiot Strode & X1/9 212210 Fiesta 211 227 ‘Mercedes Bene "240 & 300 Series 362047 2808 450 Series 314018 Peugeot 504 : : 362 044 505 Diesel “362 045 1505 Gosoline 208.211 604 311 124 Porsche stisc : 312 100 924 311122, 924 Turbo (Standard) 208.221 924 Turbo (Heavy Duty) 311 134 928 312 102 Scab 99, 900 & 900 Turbo 311 108 Volkswagen Dasher Gasoline 228 Diesel nar co 314014 Jetta, Robbit & Scirocco (Gesoline) ‘Mon. Trans. 201223, Auto. Trans. 212 208 Rabbit (Diesel) ‘Man. Trans. 314012 Auto. Trans. 312 105 Vonagen ‘Man. Trans. 211.221 Auto. Trans, 212.208 Volvo DLGL> 311 103, GLE & Coupe 311105, Diesel = ‘01257325 © ~ Bosch starter basic part number is 0 001 © ~ Volvo part number. specifications. — Starter must be mounted fo prevent meshing of pi: rion and ring gear even in engaged position. If storter has wormed up during previous tests, RPM will be higher SPECIFICATIONS Brush Length & Spring Tension Application In.(mm) ths. (9) 208 xxx 211 xxx 212 xxx 311 vex 312 xx Bld aox 362 xxx 52(13) 5213) 52(13) 3910) 3910) 52(13) 61 (15.5) 2.53.1(1150-1350) 25-2.9(1150-1300) 2'4:27(1080-1220) 2.5-2.9(1150-1300} 1.8-2.0(800-900) 2.5-2.9(1150-1300) 2.5-2.9(1150-1300) OVERHAUL DISASSEMBLY 1) Clamp starter in vise and remove nut and washer from solenoid main terminal connection, Remove solenoid mounting Screws ond guide solenoid body away from drive end housing ‘and plunger, Disconnect plunger from actuating lever. 2) Remove screws and cap with rubber seal from commutator tend housing, Wipe grease from armature shalt and remove "C” clip with shims, Remove through bolts or nuts from studs tnd lift off commutator end housing. 3) Lift springs clear of brushes and side brushes from holders. Remove brush plate from housing. Separate drive end housing ‘ond armature assembly from yoke by tapping apart 4) Remove armature assembly from drive end housing while ot the some fime uncoupling Setuoting orm, if necessary to remove actuating arm, first remove rubber insert from drive {nd housing. Remove pivot arm screw ond nut and extract ac tating erm. 5) To remove drive pinion assembly from armature shaft, Separate thrust collar from over "C” clip. Remove "C" clip from its graove and drive pinion assembly off armature shott ‘ipo 200 Rapa ema Campa r>oO-z40memStarters BOSCH (Cont.) Switch Contacts Engoging Fork Fig. 1 CLEANING & INSPECTING. Clean all pars with suitable cleaning agent, Inspect for wear for damage, then apply thin coat of oil to running surfaces. PARTS REPLACEMENT & TESTING Brushes & Springs —Check brush spring pressure with Suitable spring scale. Check brushes for minimum length and freedom of movement in holders. If replacement is necessary, reploce all brushes by cutting old brush leads midway between connection and old’ brush, Solder new brushes 10 original leads. ‘Armature ~ 1) Check commutator to shaft (or core) for short circuit with 110 volt AC test lamp. Test lamp should not light, however sight glow may occur due to dampness. Check ar: mature coils for short circuit between windings using an or mature growler 2) Check commutator for pts, urns or rough surface. If out of round exceeds .002" 05 mm}, or grooves or burned spots con not be removed with fine crocus elath, commutator must be tur Commutator Moin End Housing GD Retaining Serew Brush Assembly Bearing Bushing Brush Brush Assembly Spring Armature Disassembled View of Typical Bosch Starter red. Undercut insulation between commutator bors to a max imum depth of .024" (.6 mm). — Never use emery cloth or @ file on commutator; urn ‘on a lothe only. Bushings — Sel-lubricating bushings should be replaced only when worn or damaged. Force out bushings with suitable man: rel. Clean hole and remove burrs. Before pressing new bushing in place, sock bushing in suitable lubricant for atleast 30 minutes, Drive Assembly ~ Replace drive when damaged or teeth or worn. See Disossembly. Solenoid Plunger (Armature) ~ Plunger must move in and ‘out of solenoid body when disconnected from pinion drive lever. If corroded, clean thoroughly before proceeding with Solenoid Pull-In Coil — Connect jumper wires between o 12 volt battery ond the solenoid as shown in Fig. 2. Armature Should pullin suddenly and return when electrical connection is. broken ‘ipo 200 Rapa ema CampaStarters 3 31 BOSCH (Cont.) Hold:In Coil Pull-In Coil Solenoid Body Terminal 30 ~ Terminal 30 Ef Ih"! Hin = Solenoid Plunger (Armature) Bottery Hold:ln Coil Pullin Coil sclenod Body 2S ch Mi Terminel 30 1 I Solenoid Plunger (Armature) Ammeter PPO-740mem Fig. 2 Typical Connections for Pul-in Test Fig. 3 Typical Connections for Hold-In Test Hold-tn Coil ~ Connect jumper wires os shown in Fig. 3 white pressing armature into solencid By hond. Armature should re froin held in, Disconnect jumper terminel 50 ond ormature Should immediately return tos outer position 3) Instll brush ossembly noting thot cutouts in brush plate slide over through belts on models so equipped. On models with serews, brush plate cutouts align with loops in field windings. Plates are properly positioned when screws are in stolled in commutator end housing. Install brushes and springs = Do not attempt fo repair solenoid. I either testis un w solenoi Sssuring thot field winding brush leads do not contact yoke. satisfactory, install new solencid. REASSEMBLY 4) Slide commutator end housing into position and secure with ruts ond washers or screws, os appropriate. Install drive end housing. Install zhims onto armature shaft of commutator end 10 eliminate end play and install "C” clip in groove. 1) Slide drive pinion ossembly and thrust washer onto or moture shaft Install" clip into groove in armature shaft ond pull thrust washer up over clip. Align fork in dive end housing fond insert pivot pin. Slide armature assembly into drive end hhousing, coupling the shift fork onto the drive pinion flange, 5), Instoll bearing cap seal on commutator end housing. Lubricate end of armature shaft with lithium bosed grease ond instal bearing cap. Lubricate plunger hook and place in posi tion over shift fork in drive end housing. Install solenoid body with return spring properly positioned, then tighten mounting screws ond field connections 2) Install rubber insert in drive end housing. Guide yoke ‘assembly over armature while aligning notch with rubber in sert, Top yoke into full contact with drive end housing, STARTER PERFORMANCE SPECIFICATIONS bol ‘Amps. Volts Torque 208 xxx 35.55 {6000-8000 320-410 as 94 fulbs 78 211 wx 35-55 ‘6000-9000, 340-430 85 87 fils. ac 212 vx 35.55 ‘6000-8000 320-410 a5 9.4 ful. 75 311 axe 30-50 5500-7500 350-450 as 130 fb. 73 312 vx 5585 | 8500-10,500 | 650-730 60 137 ftlbs. 80 314 exe 50-80 7300-9300 690-780, 60 166 filbs 73 362 22x 65-95 6500-8500} 1100-1300 70 325 fs. 75 ‘ipo 200 Rapa ema Campa