Date: Mon, 21 Aug 2000 21:10:35 -0400
Reply-To: Martin Jagersand 1 <vwjag@hammer.cs.jhu.edu>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Martin Jagersand 1 <vwjag@hammer.cs.jhu.edu>
Subject: Rebuilt it yourself! Was: bosch part number for diesel starter
Dave Bayer Wrote:
> Hi-
> After not finding the starter for the diesel vanagon
> listed with anything other than VW part numbers (on any
> vendor's sites), I cleaned off my old starter enough to find
> that it is Bosch SR 28 (X). They are not cheap...
>
> dave
Bosch rebuilt starters can run near $200 nowdays, but rebuilding
it yourself is not hard. Here are some tips:
First check that it is really the starter. Measure the voltage
over the starter itself while cranking, ie from the positive
iput terminal on the starter to the starter housing. If it's
8-10V and the starter still is cranking slowly the starter is
most likely bad. If battery voltage is ok but voltage at
starter is low check voltage drop in the positive and negative
circuit. When I last measured I had .2V drop in the neg circuit
and .9V in the positive. Of the .9V .7V was over the solenoid and
.2V in ther actual cable.
So you determined that its the starter. All Bosch starters, gas
or diesel have the same basic design, but the sizes and housings
are different between different models. Get the right parts!
Wear parts are basically:
1/ Bushings: 3 total. One in each end, and one in the middle. The latter
I don't think carries much load. Cost: $2-3 each from the Bosch
distributor.
2/ Brushes: 4 in total. You can buy either a brush assembly for
$45 with the 4 brushes already mounted, or 4 loose brushes for
about $15 total. If you get loose brushes get ones with small
u-shaped metal ends welded to the copper braid. They are
much easier to solder to your brushholder.
The above is Bosch prices. VW dealer prices are about twice
as much.
Rebuild procedure:
1. Unscrew the two small screws on the commutator housing (back)
this releases the brush holder.
2. Unbolt the two studs in the back. Now the commutator end comes
off after removing a circlip on the end of the shaft, and the stator
is loose, but don't pull it off yet.
3. Loosen the 3 screws holding the solenoid to the front housing
4. Between the solenoid and the starter motor is a small rubber
piece. See if you can loosen it. Carefully wiggle and separate the
front housing.
5. Solenoid and starter can be separated at the solenoid end.
Take off the solenoid. (To prevent binding wipe off any dirt or
corrosion on the solenoid plunger before reassembly)
6. Determine shape of bushings. The gear end bushing is in the
bellhousing on starters for transverse engine models, and in the
front housing on longitudinal engines. The place front and rear bushings
if worn.
7. To get at the middle bushing remove the ring and c-clip in
front of the gear. Slide off gear assembly. Take out plate
holding middle bushing. Replace if worn.
8. Check brushes. New brushes have about 8mm between the tip and
the copper braid. I'd replace them if they are more than
half worn. Also if the bushings were really bad the starter
shaft has been riding out of center, and the brushes have been
wearing irregularly and need replacement.
9. Snip off the braided copper holding the old brushes. Don't
lose the springs! File off any remains from the brush holder.
Solder on new brushes. Mahe sure they are soldered well.
Each brush will pass 100's of amps at startup!
10. Inspect the commutator. If pitted (from arcing) file down
until clean copper. If out of round use a lathe.
11. Assemble the parts. Grease bushings and gears lightly.
You don't want grease on the commutator or so that it can
spatter on the clutch.
Useful parts numbers form the Vanagon fiche:
068 911 023 D Starter, diesel vanagon (1)
068 911 023 J Starter, diesel vanagon, alt (2)
Repair parts:
068 911 215 A Brushes
068 911 209 B Brush holder plate for 1
068 911 209 D Brush holder plate for 2
049 911 257 A Bushing, end (commutator) plate
049 911 257 Bushing, middle
059 911 257 A Bushing, gear end
068 911 320 Small parts kit, (Washers, circlip, connector strap sol-start)
068 911 491 B Stud, long, end-end.
/Martin
--
Westy 1.9l Turbo Diesel
New and used parts for sale, gas and Diesel:
http://www.cs.jhu.edu/~jager/vw/Yale/forsale.html
Martin Jagersand email: vwjag@hammer.cs.jhu.edu
Computer Science Department
Johns Hopkins University
Slow down and visit the VW diesel Westy page:
WWW: http://www.cs.jhu.edu/~jager/vw
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