Genuine Audi 80 Starter

Audi 80 Starter Parts and Q&A

• Vacuum Regulator
  034-911-209
  Q: How to dismantle and reassemble the Starter components described in the paragraph on Audi 80?

  A:

  Mark the housings and mounting bracket in relation to each other, then remove the nuts and washers to withdraw the mounting bracket. Loosen the clips and remove the heat shield if fitted. Unscrew the nut and disconnect the field winding cable from the solenoid terminal, followed by unscrewing the cross-head screws to withdraw the solenoid housing from the drive end housing. Unhook the solenoid core from the engagement lever and remove the spring if necessary. Using a socket, unscrew the through-bolts and remove them from the bearing housing, then prise out the rubber pad over the engagement lever. Withdraw the drive end housing from the yoke while prising out the engagement lever, and disconnect the engagement lever from the armature slide ring. Remove the screws to withdraw the small end cover and gasket, then extract the C-clip and remove the shim(s), noting the exact number as they determine the armature endfloat. Remove the commutator end bearing plate followed by the spacer. Before removing the brush holder assembly, obtain a socket with a diameter approximately the same as that of the commutator, locate it against the commutator, and slide the bushes and holder assembly onto the socket. Mark the engagement lever plate in relation to the yoke, then withdraw the armature. Using a metal tube, drive the stop ring off the circlip, extract the circlip, and pull off the stop ring. Slide the pinion drive from the armature. Clean all components in paraffin and wipe dry, examining them for wear and damage. Check the pinion drive for damaged teeth and ensure the one-way clutch only rotates in one direction. If the shaft bushes are worn, remove them using a soft metal drift and install new bushes that have been soaked in hot oil for approximately five minutes. Clean the commutator with a rag moistened with a suitable solvent, removing minor scoring with fine glasspaper, while deep scoring will require the commutator to be skimmed in a lathe and undercut. Check that the commutator diameter is not less than the minimum specified amount using vernier callipers. Measure the length of the brushes; if less than the minimum specified, fit new brushes, ensuring they are soldered into position without allowing solder to run down the braided wire. Reassembly is a reversal of dismantling.