Loosen the screws securing the traction relay on the front side, disengage the drive engagement lever and remove the traction relay.
Fig. 274. Sectional view of a Bosch starter.
Loosen the screws securing the casing on the rear side of the starter and remove the casing.
Unscrew the two bearing cover mounting bolts from the manifold side.
Using a puller, press out the locking sleeve from the end of the anchor shaft and remove the starter cover. Save the adjusting washers.
Remove both brushes from the brush holder and remove the brush holder.
Remove the starter housing together with the excitation windings.
Remove the drive engagement lever shaft and remove the lever.
Remove the seal from the bearing shield, paying attention to its position during installation.
Unsolder the excitation winding brushes from the winding and replace them if the excitation windings are being replaced. When replacing the excitation windings, perform the following work:
Loosen the four pole shoe mounting screws by tapping on the brass punch (see fig. 275).
Fig. 275. Unscrewing the pole shoe fastening screws using a punch.
Remove the pole shoes and remove the excitation windings together with the brushes from the shoes.
To remove the anchor or gear, you can use the recommendations in Fig. 276.
Fig. 276. The arrow shows the direction of pressing out the ring with the flange from the end of the starter drive. The retaining ring is located below.
Using a piece of pipe of the appropriate diameter, press it down (shown by arrow) flange ring and release the snap ring.
Remove the snap ring from the groove of the anchor shaft.
Remove burrs from the end of the anchor shaft.
Secure the anchor in a vice and remove the gear from the anchor shaft as shown in Fig. 277.
Fig. 277. Removing the starter drive mechanism from the armature shaft.
All details (except for excitation windings if they are to be reused) clean with gasoline and check carefully. Check the anchor windings for signs of overheating and the collector. If the collector is slightly worn, it can be cleaned with fine sandpaper; if it is heavily worn, the collector must be turned on a lathe with minimal metal removal.
Publication reprinted from this resource [MERCEDESMAN]
The starter drive gear cannot be disassembled and must be replaced if damaged. The gear must move freely along the armature shaft, otherwise it must be replaced.
The starter assembly is performed in the reverse order, as during disassembly. The minimum permissible length of the brushes is 13 mm. When installing new brushes, remove the old brushes and clean their ends, to which the wire cores are soldered, and unsolder the cores. Flatten the end of the core, place it on the new brush and solder.
When assembling the starter, pay special attention to the following points:
Place the gear on the shaft, install the thrust ring and secure the new retaining ring on the shaft. Place the thrust ring on the fixture (see fig. 278) and press a spring retaining ring into it, which will eliminate pressure on the armature shaft.
Fig. 278. Pressing the retaining ring into the thrust ring.
If it is necessary to replace the bearing bushing in the manifold cover, after pressing out the old bushing, heat the cover for 5 minutes in hot oil and press in the new bushing.
When installing the pull-in winding, check that the pusher freely engages with the drive engagement lever.
During assembly, it is necessary to apply "DZ" sealant to the places shown in Fig. 279.
Fig. 279. Letters indicate places where sealant must be applied before assembly.
The axial clearance of the anchor is 0.1...0.3 mm, it can be adjusted by installing a support washer of the appropriate thickness between the bearing sleeve in the collector cover and the retaining ring.