Repair and diagnostics of Bosch starters for VW, Audi, Skoda
In this review, we will consider the main malfunctions, problematic parts and repair methods for the Bosch starter with the catalog number 02M911023P. The starter is installed on popular cars of the VAG alliance—Audi, Seat, Škoda Superb, VW Passat, VW Golf with 1.6-2.0 liter engines.
What motors are equipped with the Bosch starter 02M911023P
The German Bosch starter with the catalog number 02M911023P was installed from the factory on engines with a volume of 1.4 to 2.0 liters on cars of the VAG concern. These engines are ALZ, ALT, BFB, BPJ, AWT, EA 827, EA 188 and a number of other units of Audi, Skoda, Volkswagen and Seat.
The Bosch 02M911023P starter is an original unit (OEM), its price for 2023 is approximately $250. However, there are analogues that are slightly cheaper, but similar in design and parameters. The most worthy owners of VAG cars consider: Their price is usually slightly lower than the original, but all the spare parts we will talk about are interchangeable. It is worth noting the first and main difference between the original Bosch starter and previous models of the 2000s. The modernized starter is unsupported. That is, earlier the starter housing was attached to the gearbox crankcase, and its shaft was supported by a brass sleeve in the gearbox crankcase. This led to the fact that the bushing wore out and the shaft got backlash. In some places, the starter gear could not engage with the engine flywheel. Thus, the starter could rotate idle without moving the engine flywheel. In the unit Bosch 02M911023P and its analogues this error was corrected, the starter became unsupported. Its basic parameters: In general, the VAG starter has a classic design—it is a 4-pole DC motor, which is powered exclusively by a battery. Like most reduction starters, the Bosch 02M911023P starter consists of: In general, the design of the Bosch 02M911023P starter is simple, which allows you to make any repairs with your own hands. Depending on the symptoms of the malfunction, the following Bosch starter parts can be considered as potentially vulnerable: The easiest option is to replace a worn-out spare part with an original or analogue. But it is also the most expensive. Only complex repair of the starter by the hands of some service center will be more expensive. Moreover, it is much more expensive. However, there are some spare parts that usually cannot be restored. Here are some examples:
Design of the starter Bosch 02M911023P
Main faults of the starter VAG 02M911023P, symptoms
Repair, solutions to the problem with the Bosch starter
Usually, repair of the spare part, if it is possible, at the service station will cost 70-80% of the price of the spare part. You can also consider buying a refurbished original starter (if the masters give a guarantee), or a used starter. In both cases, we cannot predict the service life of the unit in advance. If we do not replace worn parts ourselves.
Disassembling and defecting the VAG starter
Disassembling and defecting the Bosch starter is performed according to the following algorithm.
Unscrew the studs on the back of the housing.
Remove the complete electric motor.
Remove the stator and inspect the condition of the magnets and windings. If there is no mechanical damage, wipe it from the inside and leave it alone.
Inspect the brush gear. Wear of brushes should not be more than 30-40%, that is, not less than 7 mm. Also, there should be no traces of damage and overheating on the brushes. To remove the brush assembly, unscrew it from the back cover, remove the locking ring, the back cover.
Using a 17 mm socket (or any according to the size of the radial commutator) remove the brush gear.
Inspect the rotor, if there are no signs of damage, check the radial commutator for leakage.
To do this, one feeler of the multimeter (in the ringing mode) is placed on the shaft, the second probe touches each of the sectors of the commutator. If the radial commutator breaks through to the mass, the multimeter will signal about it.
Unscrew the pins of the solenoid and disconnect it from the housing.
Inspect the condition of the planetary gearbox.
If necessary, wash and lubricate it. There are special lubricants for closed planetary gears (Liqui Moly Thermoflex Spezialfett, Ravenol Arctic Green Crease AGG2, Castrol LMX Li-Komplexfett2, Molykote AG-650, Molykote-7514).
Also clean and lubricate the rotor shaft gear and splines on the back of the rotor shaft.
Check the condition of the front needle bearing. Most likely it will need to be lubricated. If there are signs of severe wear, the bearing should be replaced.
The roller clutch is replaced if there were cases of idling of the starter.
Assemble the starter in reverse order. And before installing it on the engine, check its functioning with a battery and wires with clamps. How to do it correctly, we figured out here.
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