Bosch Starter # 0 001 108
L1 Disassembly of starter motor
Control solenoid
Remove nut (1) securing wire to field coil. Remove securing bolts for solenoid.
L2 Bushing cover
Remove cover from housing.
L3 Bearing housing
Remove lock washers and shims, fibre washer (1) and two pin screws (2).
Remove housing.
L4 Starter body
Separate starter motor from body. Leave armature in body.
L5 Armature
Press out armature from body. Note position of fibre washer on shaft.
L6 Brushes
Remove brushes from holders. Press down on holder (1) to release lock tabs, then pull (2) to rear and lift out holders.
L7 Planet gears and Bendix drive
Remove rubber washer (1). Remove complete assembly of gears, Bendix drive and shift arm.
L8 Drive
Place suitable socket on stop ring and tap it downwards. Remove lock ring, stop ring and drive. Take care not to damage planet gear guide pins.
Remove shift arm.
Cleaning and Inspection
L9 Armature
The armature should not grind against pole shoes and field coils. Diameter of end of coil must not be more than that of armature coil. Max. radial throw 0.05 mm (0.002 in). Test armature for arcing and open circuits with appropriate test equipment.
L10 Arcing
Test commutator for arcing to ground.
L11 Commutator
Brush path should be smooth and free from dirt and oil. Machine commutator if burnt or out-of-round:
Min. diameter = 42.5 mm (1.673 in).
Max. radial throw = 0.05 mm (0.002 in)
L12 Undercutting
The insulation should be ground to 0.4 mm (0.016 in) below surface of commutator. Use a special commutator grinder or a hacksaw blade. If necessary, clean commutator with a fine-grade emery cloth.
L13 Drive
Inspect drive. Make sure that it runs correctly on thread. Check teeth. If damaged replace drive. (Also check starter motor ring gear). Check that free wheel locks in direction of rotation and disconnects in opposite direction.
L14 Bushings
Clearance between armature shaft and bushings must not exceed 0.12 mm (0.005 in).
Replace worn or damaged parts. Always replace the lock ring as it will have lost its spring force on removal.
L15 Replacement of self-lubricating bushings
Self-lubricating bushings do not wear significantly if they are treated correctly before installation.
Treating new bushings:
- place thumb over end bushing
- fill bushing with engine oil
- using index finger, press to force oil out through pores.
- Place bearing housing on a suitable support and tap out worn bushing.
- Clean bushing hole, filing any rough surfaces.
- Press in new bushing with a suitable drift.
L16 Control solenoid
Test solenoid with an ohmmeter or buzzer. Make sure that current flows between terminal 50 and ground.
Then test between terminal 50 and brush holder connection. If current does not flow there is an open circuit in the solenoid. The solenoid must therefore be replaced.
L17 Replacement of permanent magnets
Inspect magnets and replace if damaged. (Slide magnets out to remove.)
L18 Brush holders
Make sure that carbon brushes sit correctly.
Replace worn or corroded springs. If necessary use a spring balance to test spring force.
L19 Replacement of carbon brushes
Replace brushes if they are less than 13 mm (0.5 in) in length (new brushes are 18 mm = 0.7 in).
- crush old brushes
- clean cable shows with a file
- insert wire into new brush and spread out wires to form a better joint.
L20 Solder
- solder on new brushes
- hold wire with pliers to prevent solder from running. Solder quickly and with sufficient heat. On no account must solder run onto wire because this would prevent brush from sliding in its holder and weaken spring force.
L21 Planet gears
Inspect planet gears and ring gear. If worn replace complete assembly including shaft.
Assembly of Starter Motor
L22 Lubrication
Lubricate components according to instructions below. Use Bosch lubricant or bearing grease P/N 1 161 133-2 and engine oil.
1. Smear a thin layer of bearing grease on ends of shaft, shims and lock washer.
2. Oil bushing.
3. Apply plenty of grease to armature and groove for shift arm.
4. Apply a thin layer of bearing grease to armature shaft.
5. Oil bushings.
6. Apply a thin layer of bearing grease to shift arm track and solenoid core.
L23 Drive
Install drive, stop ring and lock washer on armature shaft. Slide stop ring over lock washer.
L24 Shift arm
Install:
- shift arm on drive
- insert shaft, drive and planet gears into housing
- rubber pad on top of bearing housing.
L25 Carbon brushes
Install brush holder on armature. Install brushes.
L26 Starter body and armature
Insert armature assembly into body. Note: strong magnetic force.
Install fiber washer (1) on armature shaft. Assembly starter body and housing.
L27 Rear bearing housing
Install housing. Install two pin screws (1). Place shims, fiber washer and lock washer (2) on end of shaft.
1mL28 Install bearing cover
L29 Control solenoid
Install three retaining screws. Secure wire from brush holders with a nut.
L30 Axial clearance
Check axial clearance. Clearance = 0.1 - 0.3 mm (0.0039 - 0.0118 in). Adjust using shims. Reinstall bushing cap. Test starter motor before installing in vehicle.
L31 Starter motor terminals
B+30 = from battery
50 = from ignition switch terminal 50
M = to starter motor field coils
L32 Testing
If a bench is not available, use jump leads.
Bosch 0 001 108 Exploded View:
1 Rubber washer
2 Control solenoid
3 Front bearing housing
4 Shift arm
5 Bearing bushing
6 Lock ring
7 Stop ring
8 Bushing
9 Bendix drive
10 Planet gear
11 Armature
12 Commutator
13 Starter body
14 Permanent magnets
15 Fibre washer
16 Brush springs
17 Brushes
18 Brush holder
19 Rear cover
20 Rear bushing
21 Sealing ring
22 Shim
23 Lock ring
24 Rear bearing cover
25 Rod