Starter repair (VW Golf 2)

Remove the bolts in front of the retractor relay 5 (figure 447) and disconnect the drive lever to remove the relay.



Loosen bolts 36 and remove cover 34. Loosen tightening bolts 29.

Remove the retaining rings with a screwdriver, remove the washers from the end of the shaft and remove the starter housing with the stator windings.

Remove the carbon brushes from the brush holder and remove the brush holder. Remove the starter housing from the stator winding. Remove the bolt securing the wire arm and remove the arm.



Remove the gasket from the head, paying attention to its position.

Brushes connected to the stator winding can only be replaced together with the corresponding winding as follows:

• loosen the stator pole mounting screws by hitting it with a sharp copper rod, as shown in Figure 448;
• remove the poles and windings with brushes. Before removing the anchor or overrunning clutch, remove the retaining ring (arrow in figure 449).

[The original material is available on the portal: vwmanual.ru]

Remove the retaining ring from the groove. If necessary, remove burrs from the end of the shaft.

Secure the anchor in a vice and remove the overrunning clutch from the shaft (figure 450).



All starter parts (except stator) wash in gasoline and check for burnt windings on the anchor and for scratches on the commutator. Small scratches can be removed with very fine sandpaper, large ones should be removed on a lathe. The overrunning clutch cannot be repaired and should be replaced if damaged. The starter is assembled in the reverse order. It should be determined whether the brushes have worn down to the minimum size of 131 mm. If they need to be replaced, the old brushes should be crushed with pliers and the ends of the braided wires should be cleaned. insert into new brushes, flatten from the other side and, holding from below, solder.

When assembling the starter, the following instructions must be followed:

Place the overrunning clutch on the shaft, install the stop ring and a new retaining ring. Rest the stop ring on the press plate (figure 451). Having correctly calculated the pressure on the anchor shaft, insert the retaining ring into the limiting ring.



If you need to replace the manifold bushing (it can be simply removed), then before installing a new bushing, it should be held in hot oil for 5 minutes.

When installing the solenoid relay, care should be taken to ensure that the pusher is correctly connected to the drive lever.

Cover the areas shown in Figure 452 with "D3" sealant.



The axial play of the anchor should be 0.1-0.3 mm. It can be set by changing the thickness of the adjusting washers in the starter housing and the safety C-shaped washer.