Bosch Starter # 0 001 362
Disassembly of Starter MotorK1 Bushing cap
Remove cap from rear bushing cover.
K2 Bushing cover
Remove lock washers, shims and two nuts. Remove rear cover.
K3 Brushes
Remove brushes from holders. Remove brush holder.
K4 Control solenoid
Remove nut securing cable to field coil. Remove securing bolts from solenoid.
K5 Starter motor body
Remove body from armature and drive end bearing housing.
K6 Armature
Remove:
- rubber and steel washers
- shift arm securing bolt
- armature and shift arm.
K7 Stop ring
- Tap down stop ring with a suitable socket
- Remove lock washer, stop ring and drive.
Cleaning and Inspection
K8 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.
K9 Arcing
Test commutator for arcing to ground.
K10 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).
K11 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.
K12 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.
K13 Bushings
Clearance between armature shaft and bushings must not exceed 0.12 mm (0.005 in).
Replace worn or damaged pants. Always replace the lock washer as it will have lost its spring force on removal.
K14 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 of 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.
K15 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 field coil terminal "M'. If current does not flow there is an open circuit in the solenoid. The solenoid must therefore be replaced.
K16 Starter body
Field coils must not be burnt or melted, and they must not lie higher than shoes. Test coils for open circuits and arcing using an ohmmeter or buzzer. A test lamp connected to battery can also be used.
K17 Replacement of field coil
Identify position of pole shoes with respect to starter body so that they can be reinstalled correctly. It may be necessary to use an impact screwdriver to remove pole shoes. Make sure that new coils do not short to starter body.
K18 Brush holders
Make sure that carbon brushes sit correctly. Test positive brushes holders, making sure that they do not short or arc to ground. Replace worn or corroded springs. If necessary use a spring balance to test spring force.
K19 Replacement of carbon brushes
Replace brushes if they are less than 8.5 mm (0.334 in) in length (new brushes are 16.5 mm = 0.65 in).
- crush old brushes
- clean cable shoes with a file
- insert wire into new brush and spread out wires to form a better joint.
K20 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.
Assembly of Starter Motor
K21 Lubrication
Lubricate components according to instructions below.
Use Bosch lubricant or bearing grease P/N 1161133-2 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.
K22 Drive
Install drive, stop ring and lock washer on armature shaft. Slide stop ring over lock washer.
K23 Shift arm and armature
Install:
- shift arm drive
- armature in drive end housing
- screw, nut and washer for shift arm
- pin screws.
K24 Washers
Install steel and rubber washers and solenoid.
K25 Starter body
Install starter body. Reconnect cable to solenoid.
K26 Carbon brushes
Install brush holder and then brushes. Use a feeler gauge to hold springs in position. Bend locking tabs with a pair of pliers.
K27 Rear bushing cover
Position cover. Install two nuts and place shims and lock washer on armature shaft.
K28 Axial clearance
Check axial clearance. Clearance = 0.1 - 0.3 mm (0.004 - 0.012 in). Adjust using shims. Reinstall bushing cap. Test starter motor before installing in vehicle.
K29 Starter motor terminals
B+30 = from battery
50 = from ignition switch terminal 50
M = to starter motor field coils
K30 Testing
If a test bench is not available, use jump leads.
Bosch 0 001 362...
1 Steel washer
2 Rubber washer
3 Solenoid
4 Drive end bearing housing
5 Bushing
6 Shift arm
7 Lock ring
8 Stop ring
9 Bushing
10 Centre bearing
11 Armature
12 Commutator
13 Bushing
14 Shims
15 Lock washer
16 Sealing ring
17 Bushing cap
18 Field coil
19 Pole shoe
20 Starter body
21 Screw
22 Brush
23 Brush spring
24 Brush holder
25 Bushing cover
26 Rod