Starter type Bosch DM
After removing the motor from the vehicle and cleaning it, clamp it in a vice with soft pads.
Loosen the nuts on the through bolts and remove the bracket if installed.
Remove the nut and washer securing the winding wire to the solenoid stud and separate the wire from the stud.
Remove the two screws securing the manifold end cap, then remove the cap and rubber seal.
Clean any dirt from the rotor shaft, then remove the C-clamp and shims from the ends of the shaft.
Remove the two through bolts and remove the manifold cover.
Release the brush holders together with the brushes by pushing the brush holders towards the commutator and pressing them away from the brush plate. Remove the plate (Fig. 12.9).
Remove the shank housing and armature from the yoke by gently tapping with a soft-sided hammer.
Remove the three screws and pull out the solenoid yoke, then disconnect the solenoid rotor from the lever and remove the rotor.
Remove the rubber insert from the drive shaft housing, then remove the lever axle lock nut and remove the pivot axle from the housing.
Remove the rotor assembly together with the lever from the housing.
Disconnect the lever from the gear flange.
To remove the drive pinion from the armature shaft, remove the thrust collar from the shaft using a suitable tubular punch to release the C-clamp. Once the clamp is removed, pull the thrust collar and drive pinion off the shaft.
Inspect the parts and replace any defective ones if necessary.
If the brushes are worn down to near their maximum length, replace the entire set.
The surface of the collector contacts must be clean and free of burn points. Where necessary, polish the contact surfaces with fine glass paper (just not sandpaper) and wipe with a rag soaked in gasoline.
Replace the manifold end cap and bushings (self-lubricating type) drive shaft housings, which must be kept in a clean motor environment for at least 20 minutes.
A reliable check of the anchor, collector, excitation windings and insulation requires the use of special equipment. If the electric motor does not work and the checks have not revealed any problems, it can be assumed that there is a fault in the circuit or damage to the insulation. In this case, the unit must be replaced.
Begin assembly by fitting the pinion gear and thrust ring onto the armature shaft. Install the C-shaped retaining ring in place, then use a puller to install the thrust ring.
Connect the lever to the pinion flange, then install the armature and drive lever assembly into the housing.
Install the drive lever axle and secure it with the stopper. Install the rubber insert into the casing.
Apply a little grease (lithium based) onto the solenoid hook, then install it over the actuator arm in the housing. Check that the return spring is positioned correctly, then place the yoke onto the anchor.
Install the brush plate over the end of the shaft, assemble the brush holders and springs.
Replace the manifold end cover and install the through bolts.
Install the rotor on the bearings.
Install sufficient shims on the end of the rotor shaft to eliminate longitudinal play.
Install the rubber seal onto the manifold end cap, then apply a small amount of grease (lithium based) onto the end of the shaft, secure the end cap with two screws.
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Connect the excitation winding wire to the solenoid stud and secure it with a nut and washer.
Install the bracket onto the through bolts and secure it with two nuts.
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