Starter — disassembly and assembly (Opel Zafira A)

Disassembly

1. Remove the starter (see "Starter - removal and installation").

2. Remove the starter relay (see "Solenoid Relay - Replacement").

Note: If you only need to replace the brush assembly, you do not need to remove the pull-in relay; simply unscrew the nut and remove the wire from its terminal.

3. Using a Phillips screwdriver, unscrew the two mounting screws...



...and remove the protective cover.



4. Use a screwdriver to pry up and remove the retaining ring.



5. Using a 7 mm wrench, unscrew the two starter tie bolts.





6. Remove the rear cover of the starter.



7. Use a screwdriver to pry the brush assembly out of the housing.



8. Measure the length of the brushes. If the length of one of the brushes is less than 4-5 mm, the brush assembly must be replaced.

Note: When installing the brush assembly on the rotor, it is convenient to use the socket head from the tool kit to secure the brushes in the brush holders.

9. Remove the rotor from the housing.



10. Remove the case.



11. Remove the drive lever support.



12. Remove the drive from the front cover and remove the lever from it.



13. Using a 13 mm socket head, tighten the starter drive travel limiter ring.





14. Use a slotted screwdriver to pry up and remove the retaining ring.



15. Remove the drive travel limiter ring.



16. Remove the drive.



17. Inspect the starter parts. Replace heavily worn and damaged parts.

Assembly

We install the parts in the reverse order. We press the drive travel limiter ring to the locking ring with pliers.