DIY VAZ Kalina starter repair

Starter repair Lada Kalina is a voluminous topic, and you can't put it in the framework of one short review. Let's try to at least figure out why this knot suddenly “does not twist” or does such work very hard.

One of the reasons may lie in a malfunction of the traction relay. It is indicated by characteristic clicks when starting the motor.

A burned-out winding, characteristic carbon deposits on the contact plate - this is “cured” by replacing the mentioned part. If you have some experience, you will not need to remove and thoroughly sort out the starter itself for this. If, after such a replacement, the car started up without any problems, we can say that it was lucky.

But clicks can be symptoms of a more serious breakdown, requiring a starter overhaul (in some cases - and its replacement).

The simplest diagnosis of a just removed starter is done as follows.

- Connect the terminal of the battery “earth” with one wire to the starter housing. We attach the other one to the “plus” of the battery and with the free end we bring it to the contact bolt of the traction relay (to which the wire from the starter has already been brought out). If the anchor remains motionless, the motor is faulty.

Depending on the malfunction that has occurred, the sequence and scope of repair work can be changed.

The most common starter malfunctions:

1. The winding burns out or the contact bolts and the contact plate in the traction relay burn out. To eliminate these faults, it is necessary to replace the traction relay. This can be done on the vehicle without removing the starter.

2. Defective overrunning drive clutch. To eliminate this malfunction, it is necessary to disassemble the starter and replace the drive.

3. Worn out; starter brushes. Remove the starter, replace the brush assembly and clean the manifold. When replacing the brush assembly, there is no need to remove the starter drive and the traction relay.

To complete the work you will need:

- two power wires (with clamps at the ends) for starting the engine from the storage battery of another car;

- puller for external retaining rings;

You can check the electrical part of the starter without disassembling it.

1. We remove the starter.

When checking, do not short-circuit the battery positive lead clamp to the starter housing. To do this, lengthen the clamp, for example by inserting a steel drift into it.

2. We connect the negative terminal of the battery to the starter housing with one wire. The second wire, connected to the positive terminal of the battery, is connected to the terminal bolt 2 of the traction relay, to which the starter wire is connected. If the starter armature starts to rotate, the starter motor is working properly.

3. We connect the second wire to the contact bolt 1 of the traction relay. Using a screwdriver or other suitable metal object, we short-circuit terminal 3 and the contact bolt of the traction relay. If there was a loud click and the starter armature began to rotate, it means that the traction relay is working properly.

To further check the starter, as well as to determine the cause of the malfunction, it is necessary to disassemble the starter.

1. Using a 10 mm socket wrench, unscrew the nut securing the wire tip to the terminal (contact bolt) of the traction relay.

2. Remove the wire tip from the traction relay contact bolt.

3. With an 8 mm socket wrench, unscrew the two bolts of the traction relay.

4. We remove the traction relay from the starter (in this case, it is necessary to disconnect the shackle of the relay core from the upper end of the drive lever).

Check the ease of movement of the traction relay core.Connect an ohmmeter to the traction relay terminals and, pushing the armature all the way down, make sure that the contact bolts are closed (electrical resistance is close to zero). A defective traction relay must be replaced.

5. Using a 10 mm socket wrench, unscrew the two nuts of the tie rods.

6. After carefully disconnecting the stator from the front cover, remove the stator from the awls.

7. Remove the central gear of the planetary reducer (sometimes the gear remains on the armature shaft).

8. Prying on with a slotted screwdriver, remove the three planetary gears of the reducer one by one.

Check the condition of the planetary gear. The pinion gear needle bearings must not be damaged. The gear teeth of the gearbox should not have chips, scuffs, traces of corrosion and other damage. It is necessary to replace the defective gearbox elements (either the drive or the starter assembly).

9. Resting on the top of the starter front cover with a screwdriver, pry the drive arm support.

10. We remove the drive from the cover together with the drive shaft, drive lever, lever support and external gear of the gearbox.

Check the condition of the drive. The drive must move freely, without jamming, along the splines of the shaft. The drive gear should turn freely in one direction only; chipping of teeth and strong nicks on the lead-in part of the teeth are unacceptable. Small defects can be removed with a diamond file or an abrasive bar. It is necessary to replace the faulty and badly worn drive (or starter assembly).

11... With a hammer, through a 13 mm open-end wrench, knock down the ring of the stop of the starter drive (in this case, a wooden block or a piece of dense rubber should be placed under the gear wheel of the red> ’ktor).

12. Using a slotted screwdriver, remove the stop ring of the drive travel stop from the shaft groove and remove the stop ring and travel stop ring from the shaft.

13. Remove the drive assembly from the shaft with a lever and a coupling.

14. Remove the retaining ring 1 of the drive lever clutch with a puller.

15. We remove the washer 2 from the drive 4, the clutch 5 assembled with the drive lever 3.

When replacing only the drive, further work on disassembling the starter can be omitted.

16. Remove the drive shaft support retaining ring with a puller.

17. From the drive shaft 1, we successively remove the thrust washer 5, the shaft support 4, the sealing rubber ring 3 and the outer gear of the planetary gear 2

18. Use a Phillips screwdriver to unscrew the two screws securing the brush assembly to the back cover of the starter.

19. Remove the back cover.

20. Prying with a slotted screwdriver, remove the brush assembly from the armature collector.

21... Remove the front armature shaft support.

22... Remove the thrust washer from the armature shaft

.

23... Overcoming the force of the magnets, we remove the armature from the stator.

24. We inspect the collector and armature windings.

No traces of charring of the windings are allowed - such an anchor must be replaced.

25... We clean the contaminated collector with fine-grained emery paper, clamping the armature shaft through a strip of thick paper into the chuck of the electric drill. We rinse the anchor with water with a detergent to remove dirt, coal dust and abrasive residues and wipe it dry with a clean cloth, blow it off with compressed air from a tire pump.

26... We replace worn-out brushes (the height from the working edge to the output is equal to or less than 3.5 mm) and brushes that have mechanical damage.

27... We wash the parts of the gearbox and drive with white spirit or kerosene.

You can install the brush assembly on the starter armature manifold with a special mandrel or using a tool head of a suitable size and shape. If they are absent, the brushes can be installed without these devices. For this:

1) fasten the brush assembly to the back cover of the starter with two screws;

2) we lubricate the end of the armature shaft with two drops of engine oil;

3) insert four brushes into the corresponding brush holders. By inserting the springs of the brushes into the brush holders, we put on the brush assembly on the armature collector;

4) bend the outer stops of the springs of all four brushes with pliers with thin jaws;

5) insert the spring into the brush holder;

6) holding the spring with a screwdriver, bend the four spring stops with flat pipes. Install the other three springs in the same way;

7) insert the starter armature into the stator with the brush assembly and the back cover put on it (in this case, it is necessary to hold the armature so that its collector does not come out of engagement with the brush assembly).

Further assembly of the starter is performed in the reverse order of disassembly. At the same time, we apply SHRUS-4 grease to the gearbox parts. Before installing the drive, dip it in engine oil and let the oil drain. The bushings in which the armature and drive shafts rotate, as well as the screw splines of the drive, are lubricated with engine oil;

8) to make sure that the starter is assembled correctly, we check its performance before installation. as shown at the beginning of the section

It is more convenient to work on a viewing ditch or overpass. Disconnect the terminal of the wire from the negative terminal of the battery.
Remove the air filter (see "Removing the air filter").

Disconnect the traction relay control wire.

Using the "13" head, unscrew the nut that secures the tip of the wire connected to the "positive" terminal of the battery.

... and remove the wire end.

Using the "15" head, unscrew the two nuts of the starter fastening (the lower nut is not visible in the photo).

We remove the starter.
Install the starter in reverse order.
We disassemble the starter to replace the traction relay, brush holder with brushes and drive elements.
The traction relay can be replaced on the vehicle. For clarity, we show the replacement of the traction relay on the removed starter.

Using the "13" head, unscrew the nut of the lower contact bolt of the traction relay and remove the wire tip from it.

Use a Phillips screwdriver to unscrew the two screws securing the traction relay.

... and remove it.
We take out the spring and the traction relay armature from the front cover.

Using the "8" wrench, unscrew the two tie bolts.

Disconnect the case and the front cover.

We take out the anchor with a brush holder and a back cover from the body.

Use a Phillips screwdriver to unscrew the two screws.

... and remove the back cover.
A wavy spring washer is installed in the bearing seat of the rear cover.

We remove the insulated brushes from the brush holder.

Remove the cover of the planetary gear.

We take out three satellites of the planetary gear reducer of the drive.

Remove the rubber plug.
Pressing your finger on the end of the drive shaft.

... remove the drive assembly from the front cover.

Using two screwdrivers, unclench the support eyelet and remove the drive lever.
We support the end surface of the ring gear on a wooden block. By placing the jaws of the open-end wrench "on 13" on the stop ring of the drive gear ..

... and hitting the key with a hammer, press the planetary stop ring.

We pry the locking ring with a screwdriver and remove it.
Remove the drive gear travel stop ring.

Remove the overrunning clutch from the drive gear assembly.

Using a screwdriver, slide the retaining ring out of the shaft groove and remove it.

Remove the ring gear of the planetary reducer from the drive shaft.

We insert two metal plates between the bearing and the armature collector and rest them on the jaws of the vice, striking with a hammer, through a soft metal drift into the end of the shaft, press the bearing.
By external inspection we check the condition of the collector and the armature windings. Carbonization of the windings is not allowed. If the collector is slightly burned, we clean its plates with a fine abrasive cloth. In case of severe burning and wear of the collector, the armature should be replaced. Seizure and enveloping of the plain bearing material on the journal of the armature shaft are eliminated with the finest sandpaper, followed by polishing. With an ohmmeter, we check the short circuit of the armature winding to its core. The ends of the windings should be well soldered to the lamellas. Blackening of windings and separation of varnish insulation from them is not allowed.
When the brushes are worn out, we change the brush holder assembly.
We assemble the starter in the reverse order. We mount the brush holder before installing the armature in the stator. Before installing the brush holder on the armature collector, remove the springs of all four brushes so that the brushes slide into the guides.

To do this, bend the four clips of the spring holder.

... take out the spring.
After installing the brush holder on the armature collector, install the springs and bend the spring holders. We install the back cover and attach the brush holder to it.
Apply lubricant SHRUS-4 to the gears of the planetary reducer.

We install the stop ring of the drive gear on the stop ring using sliding pliers.

When installing the case on the anchor, hold the anchor with the handle of the hammer to prevent it from being attracted by permanent magnets and lower the case onto the back cover.

In a car, the starter is a very important component. It starts the engine by driving the crankshaft into rotation for the first few revolutions. This is necessary to start the process of ignition of the mixture in the chambers.

Today we will consider this knot applicable to the popular Russian model Lada Kalina. We will tell you where it is, as well as how to remove it.

The starter includes three main components in its structure:

• traction relay operating on an electromagnetic principle;
• drive system;
• electric motor.

The unit we are considering receives power with a voltage of 12 volts from a standard battery. It is capable of developing a power of at least 1.4 kW.

With the turn of the key in the lock of the Lada Kalina ignition unit, power is supplied to the outputs of the electromagnetic relay. This element, by means of a lever, moves the overrunning clutch to a position where the starter shaft gear engages directly with the flywheel. In addition, voltage is applied to an electric motor, the shaft of which begins to rotate, driving the motor. When the motor has started, the plunger moves backward, bringing the assembly to its original position. Starter power is currently being cut off.

Many are interested in the question: where is the starter. This knot is in a rather inconvenient place if you consider the need to remove it. The starter is attached by means of pins to the end of the motor block from the side of the flywheel.

During operation, the device may malfunction, and therefore the engine will be unable to start. The Lada Kalina car assembly is characterized by the following signs of malfunction, suggesting the need for removal and diagnostics for the purpose of further repair or replacement:

• turning on the starter is accompanied by turning off other devices operating at this time;
• at the start of the device, reduced crankshaft speed is observed, which is not enough for a full start of the engine;
• turning the ignition key does not activate the starter;
• the unit is showing signs of "viability", but the engine flywheel does not rotate.

Next, we will tell you how to remove and replace.

Having found out where the necessary unit is located, we proceed to the replacement. To perform work (removal, repair and installation), you will need the following tools and devices:

• keys of dimension "8", "10" and "13";
• knob with attachments 13 and 15 mm;
• screwdrivers, both flat and cross-shaped;
• hammer, vise and pliers;
• drift (made of wood or soft metal);
• ohmmeter;
• a little grease such as "SHRUS-4";
• two metal plates, a block of wood and a fine-grained emery sheet of paper.

After the preparatory work, we figure out how to remove the device.

To make the replacement convenient, we place the LADA Kalina above the observation ditch.

1. We de-energize the on-board network (remove the terminals from the battery terminals).
2. Dismantle the air filter housing together with the element.
3. Using the key (head) on "13", unscrew the nut holding the wire tip on the positive terminal of the battery. Remove the tip.
4. With the key on "15" we unscrew the nuts fixing the starter to the engine block. We extract the node.

Installation of the device and switching with the on-board network of LADA Kalina are performed in the reverse order.

In most situations, the disassembly of the unit in the Lada Kalina model for the purpose of repair is carried out to replace such elements as:

1. brush holder in combination with brushes;
2. traction relay;
3. drive components.

Naturally, repair procedures are performed on the removed device. How to remove correctly?

This completes the disassembly procedure.

Next, we inspect the collector and the armature winding. There should be no charring here. If it is present, then with a fine sandpaper "we correct the situation." When the burning is intense, then the anchor has no alternative.

If we find scratches or enveloping the material on the shaft journal, we also use the "all-conquering" sandpaper, after which we polish the treated places.

We arm ourselves with an ohmmeter to check the closure of the core with the windings. Pay attention to the ends of the windings - their soldering to the lamellas must not be damaged. Blackening of the winding or separation of varnish insulation from its surface is not allowed.

If the wear of the brushes is evident, then we replace the holder assembly.

The assembly of the starter unit is carried out according to the reverse algorithm of actions.

So that the starter of the Lada Kalina car does not fail, it needs to carry out preventive maintenance, otherwise it will need to be replaced. Do not overheat the device by frequent attempts to start the motor. Overexposure (more than 5-7 seconds) of the ignition key in the appropriate position of the lock can also be harmful. After the 45 thousandth run of the LADA Kalina car, it is necessary to disassemble the unit, changing the lubricant and cleaning the collector surface. In addition, external contacts require inspection and cleaning.