General information
1. The sole purpose of the starting system is to ensure that the engine rotates at a speed sufficient to start it - approximately 300 rpm.
2. The starting system consists of a starter, battery, ignition switch, traction relay and connecting electrical wiring.
3. The starter is a DC electric motor with mixed excitation and an externally mounted electromagnetic traction relay. The starter consists of a housing or stator with excitation windings, an anchor with an overrunning clutch, a cover with brush holders and a traction relay.
4. When the starter is turned on, current from the battery begins to flow through the winding of the traction relay. The relay armature is pulled in and the contacts are closed. At the same time, the relay armature, through the drive lever, ensures the extension of the gear with the overrunning clutch, while the hub of the clutch rotates on the helical splines of the starter armature shaft and also rotates the gear, which facilitates the engagement of the latter with the toothed ring of the flywheel. Current flows through the closed contacts of the traction relay, feeding the stator and armature windings, and the starter armature begins to rotate together with the hub and the overrunning clutch.
5. After the engine starts, the rotation speed of the pinion exceeds the rotation speed of the starter anchor. In this case, the overrunning clutch rotates freely, and the torque is not transmitted from the engine flywheel to the starter anchor shaft. After releasing the ignition key, the power supply circuit of the traction relay windings through the ignition switch is opened, the anchor of the traction relay is pressed back to its original position by the spring, the relay contacts are opened and the drive pinion disengages from the toothed ring of the flywheel.
6. The starter with a solenoid relay is located parallel to the engine crankshaft and is fixed to the power unit.
7. When performing maintenance, it is necessary to ensure a perfect connection of the electrical wiring, remove traces of corrosion from the clamp and lubricate the terminals with a special grease.
Removal and installation
Z14XEP Engine
8. Disconnect the cable from the negative terminal of the battery (see section 9).
9. Raise the car on the lift, loosen the nut (see accompanying illustration) and disconnect the ground cable to ground.
10. Loosen the mounting nuts (see illustration 13.9) and disconnect the electrical wiring from the starter, then unscrew the 2 mounting bolts and remove the starter.
11. Installation is carried out in reverse order.
Z18XE Engine
12. Disconnect the cable from the negative terminal of the battery (see section 9) and lift the car on a lift.
13. Remove the protective bracket (see accompanying illustration) exhaust system inlet pipe.
14. Loosen the 2 mounting nuts (see illustration 13.13) and disconnect the supply wiring from the starter, as well as the ground cable.
15. Loosen the upper mounting nut and the lower mounting bolt (see illustration 13.13) and remove the starter.
16. Installation is carried out in reverse order.
Z16XEP Engine
17. Disconnect the cable from the negative terminal of the battery (see section 9).
18. Disconnect the vacuum hose (see accompanying illustration), unscrew the 2 bolts and remove the intake air duct support, then loosen the nuts and disconnect the electrical wiring cables.
19. Disconnect the ground cable (see illustration 13.18), unscrew the 2 mounting bolts and remove the starter.
20. Installation is carried out in reverse order.
Engine Z22YH (Zafira)
21. Disconnect the cable from the negative battery terminal (see section 9) and lift the car on a lift.
22. Loosen the 2 nuts and disconnect the electrical wiring cables from the starter.
23. Remove 2 mounting bolts (see accompanying illustration) and remove the starter.
24. Installation is carried out in reverse order.
Engine Z20LE(L/R/H)
25. Disconnect the cable from the negative terminal of the battery (see section 9).
26. Remove the 2 mounting bolts and disconnect the vacuum receiver mounting bracket from the intake air duct and from the engine block.
Note: The receiver is mounted at the rear top of the cylinder block.
27. Loosen the 2 nuts and disconnect the cables (see accompanying illustration) electrical wiring from the starter, unscrew the 2 mounting bolts and remove the starter.
Note: The bolts are different lengths - the top mounting bolt is longer.
28. Installation is carried out in reverse order.
Z13DTH Engine
29. Remove the battery with the tray (see section 9).
[Text copied from this portal: OPELBOOK]
30. Use an open-end wrench to press the tips (see accompanying illustration) cables from the ball joints on the gearbox. At the Opel service station, a special device (lever) Opel-KM-6042 is used for this. Pull back the clamps and remove the tips from the holder brackets and move them to the side, be careful that the tips and cables do not twist, stretch or bend.
31. With a special long key (see accompanying illustration) remove the top starter mounting bolt and then lift the car on a lift.
32. Disconnect 2 hoses from the vacuum receiver (see accompanying illustration).
33. Loosen the nut and disconnect the ground cable from the starter, unscrew the 2 bolts and remove the vacuum receiver with the support (see illustration 13.32).
34. Loosen the 2 nuts and disconnect the electrical wiring cables from the starter, unscrew the lower starter mounting bolt and remove the starter.
35. Installation is performed in the reverse order of removal. The lower starter mounting bolt should be tightened after the upper bolt.
Engine Z17DT(L/H)
36. Remove the battery and battery tray (see section 9).
37. Remove the upper mounting bolt (see accompanying illustration) starter from the gearbox housing.
Note: The starter is located at the rear of the engine block.
38. Raise the car on a lift and remove the crankcase guard (see Chapter 2).
39. Disconnect the oil filter drain hose from the engine block by loosening the mounting clamp.
40. Disconnect the tie (see accompanying illustration), unscrew the mounting bolt and nut and disconnect the starter wiring cables.
41. Loosen the ground cable fastening nut (see illustration 13.40), unscrew the lower mounting bolt and remove the starter.
42. Installation is carried out in reverse order.
Engine Z190T(L/H)
43. Disconnect the cable from the negative terminal of the battery (see Distributed 9).
44. Remove the engine cover and on Zafira models equipped with Z19DT/Z19DTL engines, also remove the cowling grille and the rear bulkhead cover of the engine compartment (see Chapter 11).
45. Release the hose (see accompanying illustration) cooling system from the holder, loosen the 2 nuts and disconnect the wiring harness holder, move the harness to the side.
46. Loosen the 2 nuts (see illustration 13.45) and disconnect the electrical wiring cables from the starter, then unscrew the 2 upper starter mounting bolts.
47. Raise the car on a lift and remove the crankcase guard (see Chapter 2), loosen the mounting nut and disconnect the ground cable, unscrew the lower mounting bolt and remove the starter.
48. Installation is carried out in reverse order.
Checking the condition and repairing the starter
49. Carrying out a detailed diagnostic of the condition and restorative repair of the starter should be entrusted to specialists of the car service - first make sure that the cost of the repair will not exceed the price of a new starter.
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