Repair of engine starter 6VD1-W (Opel Frontera B)

Disassembly

Disconnect the cable from the negative battery terminal.

Remove the starter from the engine (see the relevant chapter).

Unscrew the nut (arrow) and disconnect the wire going to the starter motor from contact M of the traction relay.



Remove 2 bolts (1) and remove the starter solenoid relay (4).

(Text copied from an internet website: OpelBook.ru)



Remove the protective plate (3) and return spring (2).

Remove 2 screws (2), remove the rear cover (3), then remove 2 clamp bolts (1) and remove the thrust washer (4).



Move the brushes (1) away from the commutator and remove the brush holder (2).





Remove the stator (2) and rotor (3). Be careful when removing the stator, as its core has a strong magnetic field.



Remove the central lock (1).

Warning: Do not place any metal objects near the rotor and stator.

Remove the rubber cushion (2), return lever (1), center plate (3) and freewheel clutch (4) with drive gear.



Remove the ball bearing (2) and bearing cap (3) from the starter front cover (1).





Remove the gear wheel (1) and satellites (2) of the planetary gear.



Remove the E-ring (arrow) from the pinion shaft.



While holding the pinion shaft, press the pinion toward the center plate, then turn the pinion clockwise or counterclockwise one tooth and remove the pinion.

Remove the thrust washer (1), center plate and pinion shaft.

Assembly

Before assembling the starter, lubricate the following parts:

• The bushing in the rear cover of the starter and the central plate;
• Planetary gears:
• Working ends of the return lever fork;
• All sliding surfaces of the gear;
• Traction relay plunger.

Install the pinion shaft, center plate and thrust washer (1).



Install the gear on the pinion shaft, press the gear to align the teeth, turn the gear clockwise or counterclockwise one tooth and then release the gear.

Install the E-ring (arrow) onto the pinion shaft.



Install the satellites (2) and the toothed wheel (1) of the planetary gear.





Install the bearing cover (3) and ball bearing (2) onto the starter front cover (1).



Install the freewheel clutch (4) with the drive gear, the center plate (3), the return lever (1) and the rubber cushion (2).



Install the center retainer (1), stator (2) and rotor (3).

Before installing the rotor, make sure that no metal objects are attracted to the rotor by its magnetic field.



Remove the brushes (1) and install the brush holder (2). Lower the brushes and make sure they are pressed against the commutator.



Install the thrust washer (4).



Install the rear cover (Z), screw in the 2 clamp bolts (1) and tighten them to a torque of 5.6 N·m, then screw in the 2 screws (2) and tighten them to a torque of 1.9 N·m.

Install the return spring (2) and the protective plate (3).



Install the starter solenoid (4) and secure with 2 bolts (1), tightening them to a torque of 4.7 Nm.



Connect the starter motor wire to contact M from the traction relay and secure with a nut, tightening it to a torque of 5.6 N·m.

Check the operation of the starter.