Phase two of replacing the starter motor contacts and plunger to a diesel R75 MGZT.
Now the starter motor is on the work bench you can start to dismantle it to replace the damage contacts/plunger or just as a preventive measure as I/we did.
Your repair kit should have two contacts and a plunger along with a short instruction leaflet.
First remove the 3 x 8mm bolt/screws holding the rear metal cover Fig 1/2
1
2
Remove the rear back plate cover inside you will see the plunger Fig 3
3
With the back plate removed slowly pull out the plunger noting the spring train this as it is re-used Fig 4
4
As you can see, even though my sons MGZT starts on the button first time, the plunger as started to pit and corrode nothing unusual after 10 years and 75,000 miles of use. Fig 5
5
Once the plunger was removed we could also see the condition of the contacts which were also pitted, Fig 6
6
First work on the left connector a 14mm ring spanner is needed to undo the nut Fig 7
7
Next remove the small washer and plastic insulator retainer Fig 8
8
Behind the insulator you will find a small rubber O-ring keep this safe as it needs to be re-used after Fig 9/10
9
10
Now you have the nut, insulator & O-ring removed you can extract the connector, push it through slowly inwards and out Fig11
11
Keep this safe as the copper bolt needs to be re-used Fig 12
12
The left side should now look like this Fig 13
13
Now you can turn your attention to the right contact this as a rubber cover and two nuts holding the copper bolt/connector into the starter pull the rubber cover back Fig 14
14
The first nut is a 12mm undo and remove keeping it safe for re-use Fig 15
15
With the nut removed you can pull off the lead Fig 16
16
Now remove the 14mm nut Fig 16a
16a
Next is the little metal washer and plastic insulator Fig 17
17
Last remove the rubber O-ring again keeping it safe as it will be reused Fig 18
18
Now carefully take a look at the contact inside of the starter motor as it as a wire connected to it, note how it fits between the copper bolt head and the contact Fig 19
19
Carefully remove the bolt from the unit Fig 20/21
20
21
With both copper bolts removed you can clean out the dirt and dust with a small soft brush, note on this starter motor the insulator as broken so that will have to be replaced also. Fig 22
22
Phase two is finished all that remains now is to replace the new connectors and plunger. Arctic
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