MAHLE Aftermarket GmbH Pragstraße 26–46

70376 Stuttgart/Germany Phone: +49 711 501-0

02
03
Preface
MAHLE is one of the most important develop- ment partners and manufacturers of
engine com- ponents and systems in the automotive industry.
The engineers at MAHLE develop products of the highest quality throughout the world
in con- junction with engine and vehicle manufacturers.
Contents
Design and function of a starter motor 1 Solenoid
The same high quality guidelines are also applied to spare parts for the
aftermarket.
Numerous checks during and after production ensure the con- sistently high quality
level of MAHLE products. If, however, unexpected failures occur in practical
operation, the causes are usually to be found in the engine environment. Operating
or assembly errors, or unsuitable operating media, may also be causes of failure.
This brochure summarizes typical damage scenarios, describes their causes, and
provides tips for avoiding similar damage in the future. This makes it easier to
troubleshoot potential causes of damage. The advice provided in the brochure helps
to ensure that our products work reliably in the long term and thus prolongs the
engine service life.
Furthermore, our experts are also confronted with complex dam- age scenarios that
go beyond the scope of this brochure. In cases where damage to our products cannot
be readily diagnosed, we are more than willing to examine them at our premises and
put together an expert damage report for you. Please contact your local sales
partner.
04 5 Starter motor
5.1 Starter motor spun out of control I 44
5.2 Starter motor spun out of control II 46
08 6 Pole windings and armature burnt 48 1.3 Malfunction III 10
12 7 Corrosion in the starter motor 50 16 8 Fuel or oil in the starter motor 52
1.1 Malfunction I 06
1.2 Malfunction II
1.4 Electrical connections charred
1.5 Housing melted 14
1.6 Copper bolt damaged
1.7 Electrical connections broken 18
2 Starter pinion
26 Our product portfolio 58 Our information services 59
9 Malfunctioning of the starter motor 54
22 Glossary 56 2.3 Teeth broken off 24
2.1 All teeth abraded on the front face 20
2.2 Partially abraded on the front face
2.4 Tooth broken off
2.5 Starter pinion and shaft discolored 28
3 Starter housing
Info at: www.mahle-aftermarket.com
3.1 Starter housing broken 30 3.2 Starter housing broken or deformed 32
4 Freewheel clutch
4.1 Grinding marks on the lock plate 34 4.2 Overrunning force uneven 36 4.3
Freewheel clutch sluggish or blocked 38 4.4 Freewheel clutch no longer
frictionally connected I 40 4.5 Freewheel clutch no longer
 frictionally connected II 42

04
05
Design and function of a starter motor
5678 91011
4
The starter motor has the task of starting the combustion en- gine. To do this,
the ignition switch needs to feed current to the solenoid. The solenoid attracts an
iron core (plunger), which mechanically (via a release fork) moves the starter
pinion into engagement with the ring gear on the engine flywheel. At the end of its
stroke movement, the iron core simultaneously closes the contact bridge, which
switches the starter motor on. In most types of starter motors, the starter motor
then uses a reduction gear to crank the engine. The starting process is complete as
soon as the combustion engine reaches its cranking speed and
starts. To do this, the ignition switch must stop feeding current to the solenoid.
A spring then returns the iron core to its starting position. This opens the
contact bridge and cuts off the supply of current to the starter motor. The starter
pinion then also returns to its starting position. Because the engine speed
increases to idle speed as the starting process ends, but the pinion is still en-
gaged with the flywheel, a freewheel clutch between the starter motor’s pinion and
shaft prevents the starter motor from over- speeding.
123
20 19 18171615
Location of pinion shaft
Flange 9 Rolling element of freewheel clutch 10 Mounting flange 11 Solenoid coil 12
Plunger 13 Solenoid 14
14 1312
Technical data
Speed required in the combustion engine to reach the point of self-sustained
operation
approx. 70–120 rpm
Speed of the starter armature at the starting speed of the combustion engine
approx. 3,000–6,000 rpm
Idle-running speed of the combustion engine
approx. 700–1,200 rpm
Current consumption of the solenoid
approx. 50–250 A
Current consumption of the solenoid holding coil
approx. 20–80 A
Current consumption of the starter motor
approx. 200–2,500 A
Starter motor output
0.8–9.0 kW
1 2 3 4 5 6 7
8 Contact bridge
T30 battery connection Commutator
Carbon brush Armature
Pole winding Reduction gear
15 Engaging fork
16 Helix
17 Meshing spring 18 Freewheel clutch 19 Pinion
20 Stop ring

06
07
1.1 Solenoid
Malfunction I
Findings: Cause(s):
n Defective earth cable or corrosion on one of the screw connections
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Contacts burnt
Contact screw overheated and melted into cover
Corrosion on the contacts
Corroded ground strap
Solenoid (opened) not overheated
n No overheating of the coil in the solenoid
n Solenoid is energized momentarily but the starter motor does not turn
n The solenoid is partially energized and then released again immedi- ately; a
clicking noise can be heard
n The solenoid does not respond when supplied with current
n Combustion engine or auxiliary aggregate is stuck
n Starter battery too weak: when the starter motor is switched on, the voltage
fails
n Contact bridge in solenoid burnt
n Contact bridge corroded
n Poor contact of the connecting cable with the starter motor and battery
Remedies/avoidance:
n Charge battery or replace if necessary.
n Check whether the combustion engine and auxiliary aggregates can be turned
mechanically.
n Check all cables for damage and connections for corrosion.
n
In case of a defective solenoid: n If the solenoid has burnt through:
replace starter motor.
check ignition switch and cable
to starter motor.
n
Never aim jet of high-pressure cleaner directly onto starter
n In case of corrosion, check at what
motor and cables.
point water has entered the starter
motor. n
Only use starter motor to move the vehicle in an emergency.
Starter motors
More

08
09
1.2 Solenoid
Malfunction II
Findings: Cause(s):
n In larger starter motors, the motor is already set into rotation with reduced
power via the solenoid connected in series. In tooth-to-tooth position, the
solenoid does not engage, which soon leads to overheating.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Solenoid overheated, indicator band heavily discolored
Solenoid overheated, indicator band slightly discolored
Solenoid significantly overheated and burnt
Fixing bolt of the solenoid with burning marks from overheated solenoid coil
n Indicator band discolored
n Coil in solenoid overheated
n No response from solenoid when supplied with current
n Indicator band inside solenoid is blackened
n Burning smell in the vicinity of the solenoid
n Coil in solenoid burnt through or short circuit in the windings.
n Starter motor actuated for too long. n Starter motor jammed (engine or
auxiliary aggregates jammed).
n Starter motor overloaded (vehi- cle moved using starter motor).
Remedies/avoidance:
n Actuate starter motor for a maximum of 30 seconds, then allow it to cool for at
least two minutes before the next starting attempt.
n For example, after changing the fuel filter, do not bleed the system by run- ning
the starter motor for a long time. It makes more sense to bleed the system using a
pump to ensure that all bubbles are removed.
n Only use the starter motor to move the vehicle in an emergency (e.g., if the
vehicle is stuck on a crossing).
n With heavier starter motors, stop the starting process immedi- ately if the motor
does not turn (tooth-to-tooth position).
Starter motors
More

10
11
1.3 Solenoid
Malfunction III
Findings:
n Starter motor is not working
n Solenoid pulls the pinion out, but
does not engage in the starter motor n Solenoid does not pull the pinion out
Cause(s):
n Heavy contamination in the sole- noid was compacted in the rear of the solenoid
by the plunger. Thick dirt deposits prevent the plunger from moving right to the
end. The distance is no longer sufficient, contact bridge is not closed.
n Heavy contamination in the sole- noid prevents movement of the plunger. This
means that the pinion does not engage and the starter motor does not switch on.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Dirt inside the solenoid
Remedies/avoidance:
n Install new starter motor.
n Clean drive end housing thoroughly.
n Clarify cause of contamination (heavy contamination in the drive end housing may
indicate a worn vehicle clutch).
Starter motors
More

12
13
1.4 Solenoid
Electrical connections charred
Findings:
n Solenoid cover melted
n Connection bolt in cover charred
n Burning marks on connection cable and bolt
Cause(s):
n Connection cable loose. Increased contact resistance and arcing on connecting
line produce local overheating.
n Connection bolt used incorrectly as a “power distributor” for other consumers.
n Excessive current consumption due to ground terminal on starter motor.
n Connection cables not fastened securely enough to vehicle. If electrical cables
start to vibrate, the nut at the connection may begin to loosen.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Loose connection has caused screw to overheat (housing melted)
Loose connection has caused screw to overheat (housing melted) Short circuit on
solenoid
Remedies/avoidance:
n Tighten connecting nut of the electrical connections with the prescribed torque.
n Ensure the connections are correctly positioned.
n Ensure that the cables are laid according to the specifications and the
insulation cannot fray.
n Fasten electric cable according to manufacturer specifications in order to
prevent cable from vibrating.
A vibrating cable can damage
the insulation and result in the nut becoming loose. A loose nut increases the
electrical contact resistance, resulting in excessive temperatures and arcing.
n Do not misuse the connections of the starter motor as a node for other electric
components. Additional cables on terminal 30 of the starter motor can lead to
electrical contact resistances.
Starter motors
More

14
15
1.5 Solenoid
Housing melted
Findings: Cause(s):
n Missing earth cable (T31) to the engine and/or transmission.
n Corrosion on the earth cable. When the engine is not running, there is an
electrical ground connection from the engine block to the pinion of
the starter motor via the bearings, crankshaft, flywheel, and ring gear. If an oil
film builds up in the crank- shaft bearings during the starting process, the ground
connection is broken. The starter motor speed drops significantly, possibly caus-
ing a heavy break spark, which may also damage the bearings.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Short circuit (burning marks on housing)
Short circuit (burning marks on housing)
n Burning marks and melted points on the housing of the solenoid or starter motor
n Connection bolt on positive pole (T30) of solenoid discolored
n Burning marks and plastic cover of the solenoid melted
n Insulation on supply line to starter motor charred
n Solenoid not working, pinion does not engage, but starter motor turns
n Solenoid not working, pinion does not engage, and starter motor only turns
momentarily
n Insulation of the positive pole (T30) supply line frayed. Short circuit to the
ground of the solenoid housing.
n Connecting nut of terminal 30 connection loosened. Either the nut was not
correctly tightened or the nut has become loose.
n Positive pole (T30) supply line not fastened according to manufacturer
specifications. The connecting nut has become loose as a result of
the heavy copper cable vibrating.
n Terminal 50 connection cable (coming from the ignition switch) inadvertently
connected to the supply line to the starter motor (T30).
Remedies/avoidance:
n Check all electric cables, insulation, cable grips, and connections for damage.
n When removing the starter motor, mark the cables and connections.
n Remove corrosion from connections.
n Check that all earth cables on the vehicle and on the drive unit are connected
correctly. Carefully remove corrosion from the connections.
n Tighten connecting nuts of the electrical connections with the prescribed torque.
n Ensure the connections are correctly positioned.
n Ensure that the cables are laid according to the specifications. Do not misuse
the connections of the starter motor as a node for other electric components.
Starter motors
More

16
17
1.6 Solenoid
Copper bolt damaged
Findings:
n Thread on connection bolt damaged
n Connection bolt stretched, in some cases with visible necking in the thread
n Connection bolt torn off
Remedies/avoidance:
n Only tighten the nut on the copper bolt with the permitted torque:
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Nut on connection tightened too much and thread damaged
Nut on connection tightened too much and bolt torn off
Bolt thread overtightened
Cause(s):
n Connecting nut tightened too much
M8: 10 Nm ±2 Nm M10: 15 Nm ±3 Nm M12: 21 Nm ±3 Nm
Starter motors
More

18
19
1.7 Solenoid
Electrical connections broken
Findings: Cause(s):
n Battery cable not secured firmly enough, in conjunction with strong vibrations.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Terminal 30 connection torn out
n Solenoid cover torn off
n Solenoid cover broken
n Connection bolt completely torn out
n Transport damage.
n Connection bolt knocked during
installation of starter motor.
n If the starter motor still worked a few times, the plastic housing was only
cracked. Actuating the starter motor has increased the size of the crack.
Remedies/avoidance:
n Do not drop or throw the starter motor.
n When installing the starter motor, do not knock any components in the engine
compartment.
n Replace starter motor.
n Secure cables to eliminate/ prevent vibrations.
Starter motors
More

20
21
2.1 Starter pinion
All teeth abraded on the front face
Findings: Cause(s):
remain in the extended position and is slowly pushed back to the starting position
by the rotating combustion engine.
n If the solenoid is activated for too long via terminal 50 (T50), the tem-
perature increases, along with the internal resistance. This causes the solenoid to
lose power, resulting in the pinion being pushed back to the starting position by
the rotating combustion engine.
n Install a start-locking relay to prevent unintentional starting while engine is
running.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
All teeth on front face of pinion worn
Additional start-locking relay prevents starting while engine is running
n All teeth on front face of the pinion worn or abraded
n Heavy contamination on starter shaft and pinion
n All teeth on front face of the pinion are worn or abraded and the solenoid is
thermally damaged
n Starter motor was started while the engine was running. Pinion cannot engage in
the ring gear. As a result, the front faces of all the pinion teeth are damaged by
the ring gear (operating error).
n Starter motor engages automatically in the running engine. In case of heavy
contamination, the pinion may
Remedies/avoidance:
n Check starter pinion and ring gear for damage and replace if necessary.
n Check that ignition switch works correctly, replace if necessary.
n Check connection cable from ignition switch for damage to insulation.
n If the starter motor is switched via a relay, the relay must be replaced.
30
30
W
50
Starter motors
86 Relay
85
30
87
30 50
More

22
23
2.2 Starter pinion
Partially abraded on the front face
Findings:
n One or more pinion teeth are abraded on the front face
n The damaged areas often have a blue discoloration
n Starter motor is usually jammed (cannot turn in any direction)
Cause(s):
n Starter motor and freewheel clutch are jammed—as a result, pinion is also stuck.
When pinion is disengaged, only one or two pinion teeth are worn.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Individual pinion teeth are worn
Remedies/avoidance:
n Clarify cause of starter motor failure (see damage scenario “Starter motor spun
out of control”) and replace starter motor.
n Check ring gear on flywheel for damage along entire circumfer- ence and replace
if necessary.
n Clean drive end housing and remove all foreign objects.
n Check key switch and supply lines.
Starter motors
More

24
25
2.3 Starter pinion
Teeth broken off
Findings: Cause(s):
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Tooth broken off on starter pinion (mechanical overload)
Broken starter pinion (mechanical overload)
n Cracks on one or more pinion teeth (forced rupture)
n One or more teeth completely broken off (forced rupture)
n Pinion broken
n In some cases, the shaft and/
or flange are also broken
n Mechanical overload as a result of engine misfiring
n Mechanical overload due to starting when the engine is coming to a stop
n Mechanical overload as a result of using a battery that is too large or a second
battery
Remedies/avoidance:
n Check valve timing and carburetion and correct if necessary.
n After a failed starting attempt, wait until the engine has come to a complete
stop.
n Install a start-locking relay with a time delay adjusted to the specific
application.
n Use correct battery size according to vehicle manufacturer’s specifications.
Starter motors
More

26
27
2.4 Starter pinion
Tooth broken off
Findings:
n One or more pinion teeth are dam- aged in the center (forced rupture)
n Starter shaft broken (forced rupture) n Ring gear mechanically damaged
Cause(s):
n Foreign objects (bolt, spring, parts of the clutch) have become loose and ended
up between the ring gear and the pinion during the starting process. This has
caused the starter motor and ring gear to become mechanically overloaded.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Foreign object damage on pinion
Pinion broken off
Foreign object damage on pinion, starter shaft broken
Remedies/avoidance:
n Replace starter motor. n Replace ring gear, as there will be severe damage to at
least two teeth.
n Remedy cause (replace vehicle clutch, pressure plate, and/or thrust bearing).
Starter motors
More

28
29
2.5 Starter pinion
Starter pinion and shaft discolored
Findings: Cause(s):
n Freewheel clutch damaged as a result of starting when the engine was coming to a
stop
n Freewheel clutch clogged or overheated (grease leaked)
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Blue thermal discoloration on starter shaft
Significant run marks on pinion (front and back)
n Blue discoloration on starter shaft and pinion
n Significant run marks on the front and back of the tooth flanks
n Bearing bush of the pinion worn
n Heavy contamination in the vicinity
of the starter jaw
n Freewheel clutch sluggish, jammed, or without power
n Pinion not disengaged after starting, causing it to run along the ring gear
n Heavy dirt and dust contamination on the starter shaft, pinion, and/or helix
n Electrical defect in the solenoid actuation
n Starter motor actuated for too long (starting problems, improper ven- tilation of
the fuel system, etc.)
Remedies/avoidance:
n Install new starter motor; check ring gear for wear and replace if necessary.
n Check electric actuation of the starter motor (key switch, cables, relay).
n Ensure that the starter motor is only actuated for a short period of time. It is
advisable to engage the starter motor for no more than 30 seconds and to then let
it cool for 2 minutes.
n Clean drive end housing thoroughly.
n Clarify cause of contamination (heavy contamination in the drive end housing may
indicate a worn vehicle clutch).
Starter motors
More

30
31
3.1 Starter housing
Starter housing broken
Findings:
n Starter motor flange broken (forced rupture)
n Shaft broken (forced rupture) n Cracks on one or more pinion
teeth (forced rupture)
Cause(s):
n Mechanical overload as a result of engine misfiring
n Starting when engine was coming to a stop
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Bearing cap on starter motor broken as a result of mechanical overload
Starter shaft broken as a result of mechanical overload
Remedies/avoidance:
n Check valve timing and carbure- n After a failed starting attempt, tion and
correct if necessary. wait until the engine has come
to a complete stop.
n Install a start-locking relay with a time delay adjusted to the specific
application.
Starter motors
More

32
33
3.2 Starter housing
Starter housing broken or deformed
Findings:
n Mechanical damage to housing n Mechanical damage to the rear
bearing cap
Cause(s):
n Transport damage
n Starter motor damaged during
installation
n Starter motor tilted during assembly n Starter motor dropped
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Transport damage to starter housing
Transport damage to the flange
Transport damage to the flange
Remedies/avoidance:
n Do not drop or throw starter motor (even when still in the packaging).
n Install starter motor carefully and do not try to pull it into position with the
fixing bolts.
Starter motors
More

34
35
4.1 Freewheel clutch
Grinding marks on the lock plate
Findings:
n Grinding noises during starting process
n Contact marks from the flywheel/ gear wheel on the front face of the freewheel
clutch
n The lock plate is abraded, causing the rollers and springs to fall out of the
freewheel clutch
Cause(s):
n Starter motor is not suitable for the vehicle. Starter motor pinion extends too
far for this engine. Freewheel clutch comes into contact with the ring gear of the
flywheel.
n Ring gear has come free of the flywheel or was incorrectly mounted on the
flywheel.
n Flywheel is severely crooked or wobbly (assembly defect).
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Grinding marks from the flywheel on the guard plate of the freewheel clutch
Grinding marks from the flywheel on the guard plate of the freewheel clutch
Remedies/avoidance:
n Only use the appropriate starter motor
n Check that the ring gear is positioned correctly on the flywheel.
for the application.
n If it is unclear which starter
motor is right for the application, compare all dimensions of the old starter motor
and the stroke of the freewheel clutch (with pinion) with the new starter motor.
Starter motors
More

36
37
4.2 Freewheel clutch
Overrunning force uneven
Findings: Cause(s):
Solenoid
Starter pinion
Starter housing
Impressions on the cylindrical part of the pinion from the rollers of the freewheel
clutch
Roundness measurement on the cylindrical part of the pinion
n Cracks on one or more pin- ion teeth (forced rupture)
n One or more teeth completely broken off (forced rupture)
n Pinion broken
n Overrunning force uneven
n Mechanical overload as a result of engine misfiring.
n Mechanical overload due to starting when the engine is coming to a stop.
Remedies/avoidance:
n Check valve timing and carburetion and correct if necessary.
n After a failed starting attempt, wait until the engine has come to a complete
stop.
n Install a start-locking relay with a time delay adjusted to the specific
application.
5,000 μm
Starter motors Freewheel clutch
Gauss 50%
180°
90°
270°
More

38
39
4.3 Freewheel clutch
Freewheel clutch sluggish or jammed
Findings:
n Freewheel clutch is jammed
n Significant wear marks on the front
and back of the pinion tooth flanks
n Heavy contamination in the freewheel clutch
n Grease in the freewheel clutch has become resinous and mixed with dirt and dust
Cause(s):
n Contamination and dust thicken the grease in the clutch. Rolling elements and
springs are wedged and jammed.
n Freewheel clutch was thermally overloaded, for example, because the pinion was
engaged for too long. As a result, the grease filling has become resinous and the
rolling elements and springs are sticky.
n Freewheel clutch was thermally overloaded. As a result, the plastic rolling
element cage has melted and bonded with the springs and rolling elements as it
cooled down.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Pinion with freewheel clutch overheated, rolling element cage melted
Significant run marks on pinion (front and back)
Freewheel clutch heavily contaminated
Remedies/avoidance:
n Replace starter motor.
n Prevent the pinion from running
along the ring gear for too long.
n Also install a start-locking relay.
n Clean drive end housing thoroughly.
n Clarify cause of contamination (heavy contamination in the drive end housing may
indicate a worn vehicle clutch).
Starter motors
More

40
41
4.4 Freewheel clutch
Freewheel clutch no longer frictionally connected I
Findings: Cause(s):
n If the starter motor is actuated when the engine is coming to a stop,
the radial force generated by the rolling elements in the guide tracks can be so
large that the housing of the freewheel clutch bursts. As a result, the rolling
elements can no longer transfer sufficient force. At the same time, the compressed
lock plate is dilated and comes
free of the housing. Eventually, the rolling elements and springs fall out.
n Install a start-locking relay with a time delay adjusted to the specific
application.
n Check electric actuation of the starter motor (key switch, cables, relay).
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Housing of freewheel clutch overloaded and cracked
Housing of freewheel clutch overloaded and cracked
n Combustion engine does not turn during the starting process, although the pinion
engages and the starter motor turns
n Pinion can be twisted in both directions
n Lock plate of the freewheel clutch is loose or has fallen off
n Rolling elements and springs are completely or partially missing
n Mechanical overload as a result of engine misfiring.
n Freewheel clutch mechanically overloaded as a result of starting when the engine
was coming
to a stop.
Remedies/avoidance:
n Install new starter motor; check ring gear for wear and replace if necessary.
n Check valve timing and carburetion and correct if necessary.
n After a failed starting attempt, it is very important to wait until the engine
has come to a complete stop before attempting to start the engine again.
Starter motors
More

42
43
4.5 Freewheel clutch
Freewheel clutch no longer frictionally connected II
Findings:
n Combustion engine does not turn during every starting process, although the
pinion engages and the starter motor turns
n Pinion can be twisted in both directions.
n Heavy contamination in the vicinity of the pinion, freewheel clutch, and helix
n Dust, clutch abrasion particles, oil, and grease form a sticky paste in the
vicinity of the pinion, shaft, and freewheel clutch
n Pinion remains engaged for a long time even though the start-
ing process has ended
Cause(s):
n Leaking engine or transmission oil combines with contamination to form a sticky
paste. This hinders the axial movement of the pinion on the shaft. The spring of
the de-ener- gized solenoid pulls the mechanism back more slowly or not at all. The
pinion remains engaged for a long period of time and rotates along the flywheel of
the combustion engine.
n The release fork mechanism is sluggish.
n Freewheel clutch is overloaded as
a result of the pinion being engaged in the ring gear for a long time.
n Grease leaks from the freewheel clutch as a result of thermal load. From time to
time, rolling elements and springs become wedged, jammed, or worn.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Starter motor and freewheel clutch heavily contaminated
Freewheel clutch and helix heavily contaminated
Remedies/avoidance:
n Install new starter motor; check ring gear for wear and replace if necessary.
n Locate and rectify cause of oil leakage (shaft seal rings on engine and
transmission, crankcase ventilation on engine clogged).
n Clean drive end housing thoroughly.
n Clarify cause of contamination (heavy contamination in the drive end housing may
indicate a worn vehicle clutch).
Starter motors
More

44
45
5.1 Starter motor
Starter motor spun out of control I
Findings:
n Rear bearing cap on the front flange of the starter motor twisted (can be easily
identified by the two housing screws)
n View through the bore of the drainage tube: fibers and destroyed compo- nents
visible inside the starter motor
Cause(s):
n Overspeeds on the starter motor armature due to damage to the freewheel clutch.
If the freewheel clutch is jammed and the engine goes from the starting speed to
idle speed, the starter motor speed also
increases tenfold. If the combustion engine is then brought to operating speed, the
armature speeds increase to well over 100,000 rpm (instead of 5,000 rpm). This
creates such strong centrifugal forces that the armature and commutator are broken
down into their individual components.
n Freewheel clutch jammed. Mechan- ical damage due to starting when the engine was
coming to a stop.
n Freewheel clutch jammed. Mechanical damage due to the pinion running along the
ring gear for too long.
n Heavy contamination in the vicinity of the pinion and shaft.
n Install a start-locking relay to prevent inadvertent actuation of the starter
motor.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Rear bearing cap opposite the flange twisted
View into the drain hole
Rear bearing cap broken; rotor and commutator spun out of control
Commutator has started to break apart
Armature winding and fiberglass ring of the armature spun out of control; New
starter motor for comparison commutator and brushes destroyed
n Rear bearing cap destroyed
n Fiberglass ring to reinforce the arma-
ture windings has been destroyed (rear bearing cap is full of glass fibers)
n Some copper elements of the commutator have come free of the assembly; brushes
are heavily worn
Remedies/avoidance:
n Install new starter motor; check ring gear for wear and replace if necessary.
n After a failed starting attempt, it is very important to wait until the engine
has come to a complete stop before attempting to start the engine again.
n Check electric actuation of the starter motor (key switch, cables, relay).
n Ensure that the starter motor is only actuated for a short period of time. It is
advisable to engage the starter motor for no more than 30 seconds and to then let
it cool for 2 minutes.
n Commutator has broken down into its individual components
n Brush holders and carbons have been crushed
n If the starter motor is shaken, rattling noises can be heard in the rear section
Starter motors
More

46
47
5.2 Starter motor
Starter motor spun out of control II
Findings:
n Rear bearing cap on the front flange twisted (can be easily identified by the two
inclined housing screws)
n Melted areas on the bearing cap as a result of arcing (short circuit between
brushes and bearing cap)
n Fiberglass ring to reinforce the arma- ture windings has been destroyed (rear
bearing cap is full of glass fibers)
n Brush holders and carbons have been crushed
n Commutator has broken down into its individual components
n Rear bearing cap destroyed n Armature windings heavily
thermally discolored
n Heavy thermal discoloration on the commutator
n
Overspeeds on the starter motor armature due to damage to the freewheel clutch.
n
Freewheel clutch jammed. Mechan- ical damage due to starting when the engine was
coming to a stop.
Solenoid
Starter pinion
Freewheel clutch Starter housing
Rear bearing cap of the starter motor broken as a result of spinning out of control
and melted after coming into contact with the brush
Brush holder destroyed as a result of the armature spinning out of control
(overspeed)
Commutator totally destroyed (extreme overspeed)
Rear bearing cap of the starter motor melted after coming into contact with brush
Rear bearing cap opposite the flange twisted
- -
Remedies/avoidance:
n Install new starter motor; check ring gear for wear and replace if necessary.
n Check electric actuation of the starter motor (key switch, cables, relay).
n Ensure that the starter motor is only actuated for a short period of time.
Cause(s): n
n Defect on the key switch or supply line, resulting in the starter motor being
permanently supplied with current.
It is advisable to engage the starter motor for no more than 30 seconds and to then
let it cool for 2 minutes.
n Use the starter motor with the output indicated in the man- ufacturer
specifications.
n
Check whether the engine and all connected units can be turned easily.
n
Freewheel clutch jammed. Mechan- ical damage due to an excessively long starting
process.
At the time of the overspeeds resulting in damage, the starter motor was still
being supplied with current. As a result, there may have been a short circuit
between the brush holder and housing cover.
n
Install a start-locking relay to pre- vent inadvertent and excessively long
actuation of the starter motor.
Starter motors
More

48
49
6. Pole windings and armature burnt
Findings: Cause(s):
n With excessive power takeoff
at the starter motor, the starter motor speeds fall, while the current consumption
of the starter motor increases to several times its normal value. This results in
extreme heat being generated within the component.
n Damage process: starter motor overheats, enamel insulation burnt, short circuit
in the wind- ings, and short circuit to ground.
n Only use the starter motor to move the vehicle in an emergency (e.g., if the
vehicle is stuck on a crossing).
n After changing the fuel filter, do not bleed the system by running the starter
motor for a long time; instead, bleed the system with a pump to ensure that all
bubbles are removed.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Brown discoloration on the pole winding insulation (pole windings overheated)
Starter motor armature thermally overloaded (discoloration)
Burning marks on the commutator of the starter motor
- -
Remedies/avoidance:
n Pole winding insulation burnt or shows a dark discoloration
n Armature discolored (annealing colors) n Enamel insulation of the copper
windings in the armature burnt or shows a dark discoloration
n Commutator thermally discolored n Burning marks on the surface of
the commutator
n
Starter motor actuated for too long (starting problems, improper ventilation of the
fuel system).
n
No or far too little rotation of the starter motor during the starting process
(engine jammed or sluggish).
n
Vehicle was moved using the starter motor.
n Replace starter motor.
n Clarify and eliminate the cause of
the sluggishness of the combus- tion engine and connected units.
n Check whether key switch, relay, and cables were also affected.
n
Ensure that the starter motor is only operated for a short period of time. It is
advisable to engage the starter
motor for no more than 30 seconds and to then let it cool for 2 minutes. After the
third unsuccessful attempt at starting, the starter motor requires a cooling period
of 30 minutes.
Starter motors
More

50
51
7. Corrosion in the starter motor
Findings:
n Solenoid is not being energized
n Solenoid is energized but the main current for the starter motor is not applied
n Reduced starter motor speed
n Insufficient starter motor output
n Corrosion in the solenoid, in the retaining spring and plunger, and on the
contact bridge
n Corrosion in the starter motor (arma- ture, commutator, brush holder, etc.)
n Drain hose is missing or defective
Cause(s):
n Starter motor was under water. (Starter motors are only splash-proof!)
n Starter motor was actuated under water. Movement of the solenoid and pinion
causes a pump movement.
n Starter motor installed in the wrong direction (drain hose facing up).
n Water ingress as a result of the engine being cleaned incorrectly with a high-
pressure cleaner.
n Damage to starter motor gaskets.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Corrosion on the solenoid
Corrosion on the starter motor
Corrosion inside the starter motor
- -
Remedies/avoidance:
n Replace starter motor.
n When cleaning the vehicle or engine, do not direct the water jet straight onto
electric components.
n Ensure that the correct installation orientation is observed (drain hoses must
always point downward).
n Ensure that the drain hose is seated properly.
n Avoid driving through deep pools of water.
n Never start the engine if the starter motor is below the water line.
n If the starter motor fails sporadi- cally, install a new starter motor.
Starter motors
More

52
53
8. Fuel or oil in the starter motor
Findings:
n Insufficient starter motor output
n Reduced starter motor speed
n Bridged copper segments of the commutator (carbon dust)
n Burning marks and discoloration on the commutator
n Brushes soaked with fuel or oil
n Despite a low mileage, carbon brushes are very heavily worn
Cause(s):
n Ingress of fuel or engine oil in the starter motor
n Brushes are saturated with fuel or oil, leading to increased brush sparking and
heavy abrasion
n Abrasion becomes paste-like (rather than dusty) and causes bridges and short
circuits in the commutator
n Abrasion becomes paste-like (rather than dusty) and can cause a short circuit to
ground at the brush holders
n Leaks in the fuel filters and lines
n Oil loss in the engine or transmission n Oil loss in the hydraulic system
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Abrasion particles from the carbon brushes on the commutator
Oil in the starter motor
Sticky abrasion particles from the carbon brushes all around the brushes
Mixture of oil and graphite dust in the bearing cap
-
Remedies/avoidance:
n Abrasion particles from the carbon brushes are visibly adhered to the sides of
the brushes and brush holders
n Replace starter motor.
n Locate and repair leaks in the engine.
n Clean engine and transmission thoroughly.
n Check hydraulic pump, lines, and cylinders and replace or seal.
Starter motors
More

54
55
9. Malfunctioning of the starter motor
Direct drive starter motor (without reduction gear)
Findings:
n Combustion engine does not start
n Starter motor turns too slowly
n Starter motor turns sluggishly
n Grease escaping at the protection cap on the rear bearing cap
n Axial bearing disc on the rear bearing cap jammed
n Significant grinding marks on the front face of the commutator
n Significant grinding marks on the rear bearing cap
n Support plate wedged
n Wear marks on the support plate
and washer
n Large burr/ridge on the shaft groove
Cause(s):
n The battery installed was too powerful. n An additional battery was subse-
quently installed in the vehicle.
n Connection cable from battery to starter was replaced by a cable that was too
large.
n The consequences:
Solenoid disengages the pinion too forcefully.
If the pinion hits the stop ring too powerfully, the shaft and commutator are
pulled out of the armature piece by piece.
Axial bearing disc at the back
end of the shaft is wedged and inhibits the starter motor.
Solenoid
Starter pinion
Starter housing
Freewheel clutch
Support plate in the bearing cap heavily tarnished
Support plate in the bearing cap heavily tarnished
Support plate in the bearing cap heavily tarnished
- -
Remedies/avoidance:
n Replace starter motor.
n Use starter battery in accordance with the engine manufacturer’s instructions.
n Never use a starter battery that is too powerful.
n Use a cross section of the connec- tion cable in accordance with the
specification.
n If possible, replace the direct drive starter motor with a starter motor with
reduction gear. In a starter motor of this type, the pinion shaft and armature
shaft are separated mechanically by the reduction gear.
Starter motors
More

56 57
Glossary Glossary
Term
Explanation
Term
Explanation
Operating time
A starter motor is designed to be actuated for a maximum of 30 seconds per start.
If actuated for longer, there is a risk of overheating.
Permanent magnet
Most starter motors have electromagnetic coils that form a stator. In some
applications, permanent magnets are installed in the stator housing instead of
coils.
Pinion
The pinion is a small gear wheel on the starter motor. During the starting process,
it engages in the ring gear of the combustion engine and turns it.
Plunger
The plunger is the iron core of the solenoid. When the solenoid coils are supplied
with current, the iron core moves both the pinion and the spring-mounted contact
bridge via the engaging lever.
Pole winding Electromagnetic coils in the stator housing of the starter motor.
Power output In the case of direct current, the real power P is the product of
the voltage U and the current I.
Pull-in winding Coil in the solenoid that pulls the plunger into the solenoid
during the starting process.
Reduction gear
The reduction gear (planetary gear) reduces the pinion speed, increasing the torque
accordingly. Thanks to the transmission ratio, the starter motor has a smaller
design than a direct drive starter motor, with the same power output.
Relay Electromagnetic switch that can turn large working currents on or off using
small control currents.
Ring gear The ring gear is part of the flywheel. During the starting process, the
pinion engages in the ring gear.
Sealed noseless starter motor Starter motor without a flange. The starter shaft
is not countersupported at the front.
Self-sustaining speed
The speed necessary to bring a combustion engine to the point of self-sustained
operation. Generally, it is approximately one tenth of the idle-running speed.
Solenoid
Electromagnet that moves the pinion into engagement with the ring gear during the
starting process and then energizes the starter motor.
Start-locking relay A relay that prevents the starting process from being
initiated when the combustion engine is running.
Starter motor performance curve
Performance curve (torque, rotational speed) and current consumption of a starter
motor.
Starter motor with flange Starter motor design in which the pinion shaft is
additionally fastened and mounted on the front end.
Stop ring Metal ring at the front end of the starter shaft, designed to restrict
the pinion’s path of contact.
Torque of copper bolt M8: 10 Nm ±2 Nm, M10: 15 Nm ±3 Nm, M12: 21 Nm ±3 Nm
Transport damage External damage to the component caused by improper handling.
Water drain
On the bearing cap, there is a bore at the lowest position (ensure correct
installation position). If condensation water collects in the starter motor, it can
drain here.
Water drain, drain hose
To prevent the water spray from getting into the starter motor via the water drain,
the drain hose bends when water is spraying out.
Armature Rotor of the starter motor.
Bearing cap
Rear cover of the starter motor. This cap contains the starter shaft and protects
the starter motor against ingress of dust and liquids.
Burning marks Melting of metallic components due to arcing.
Carbon brush Transfers the currents to the sliding contacts (commutator) of the
rotating armature.
Commutator
Sliding contacts on the armature that conduct the current from the carbon brushes
to the corresponding armature windings (coils).
Contact bridge
Electrical switch in the solenoid. As very high working currents of several hundred
amps need to be conducted in the starter motor, the contact bridge consists of a
thick copper plate.
Current consumption
The amount of current that a starter motor takes from the battery. The current
consumption is dependent on the required torque, starter motor speed, and capacity
of the battery.
Direct drive starter motor Starter motor without reduction gear—the shaft is made
from one continuous piece.
Dust-proof Design that does not allow any contaminants to enter the starter motor
in very dusty environments.
 Dust-protected Design that allows very few contaminants to enter the starter
motor in dusty environments.
Enamel insulation
Insulation made of synthetic resin for copper wires. Copper wires for coils usually
come with enamel insulation. As the insulation is very thin, more windings can be
fitted into a small installation space.
Engaging The pinion teeth mesh with the teeth of the ring gear.
Engaging lever Rotatable lever via which the solenoid moves the pinion into
engagement with the ring gear of the flywheel.
Fiberglass ring
The copper coils in the armature are also fixed in place using a ring made of glass
fiber-reinforced plastic. The fiberglass ring prevents the windings from being
flung out of the armature by centrifugal forces.
Flange Special starter motor design in which the pinion shaft is additionally
fastened and mounted on the front end.
The flywheel (also known as the flywheel mass) is used to store the rotational
energy of the combustion engine. Flywheel The flywheel compensates for the uneven
acceleration of the crankshaft. The ring gear, via which the starter
motor starts the engine, is fastened to the flywheel.
The starter motor drives the pinion using a frictional connection. As soon as the
engine reaches the point Freewheel clutch of self-sustained operation, the engine
speeds increase. The freewheel clutch interrupts the transmission
of power in a backward direction from the engine to the starter motor.
Ground terminal
The starter motor is generally grounded via the housing. In some applications
(e.g., boat engines), the starter motor has a separate ground terminal.
Helix
Helix thread on the pinion shaft. Its task is to cause the pinion to rotate
slightly when it engages, allowing it to engage more easily. This prevents “tooth-
to-tooth” positioning as far as possible.
Hold-in winding
Coil in the solenoid that pulls the plunger into the solenoid during the starting
process and holds it there throughout the process.
Ignition switch The ignition switch is used to actuate the starter motor at
terminal 50 on the solenoid.
A special paper band wound around the coils of the solenoid. If the solenoid is
thermally overloaded Indicator band (actuated for too long), the indicator band
becomes discolored. This makes it possible to verify that
overloading has occurred.
Meshing spring
The pinion is flexibly mounted with the meshing spring. This acts as a protection
in case the pinion and ring gear are positioned tooth to tooth.
Mounting flange Front housing with which the starter motor is fastened to the
combustion engine or transmission.

58 59
Our product portfolio
n Pistons n Valve train components
n Piston rings n Cylinder kits
n Cylinder liners n Turbocharger & retrofit/special kits n Bearings
n Oil seals n Sealants n Head bolts
Our information services
Engine components
Quality built to last—precise fit and long life
Gaskets
Gasket range available worldwide for over one million applications
Filters
Our filter range—a clean solution
n Air filters n Air drier cartridges
n Oil filters n Transmission oil filters
n Fuel filters n Urea filters
n Cabin filters n
n Technical Messenger
Valuable technical information and the latest tips on all aspects of the mainte-
nance and repair of MAHLE products (see under “Services” on our website)
n Technical posters
n Damage brochures
n Installation videos and animations
A/C refrigerant charge and A/C compressor oil filling quantities manual
Engine cooling & A/C
Comfort you can feel—now and in the future
n Radiators, charge air coolers n A/C compressors, A/C condensers
n MPULSE customer magazine
n Fans & clutches, condenser/radiator fans
n Expansion tanks, cabin heat exchangers
n Exhaust gas recirculation coolers, oil coolers n Water pumps & kits
n Thermostats, thermal switches
n Starter motors n Alternators
n Actuators & switches
n High-performance electronics
n TechPRO® diagnostic kit
n TechPRO® Digital ADAS
n ArcticPRO® A/C service
n FluidPRO® automatic transmission flushing
n Filter-driers & accumulators, A/C compressor oils
n Evaporators, expansion valves, orifice tubes
n Interior blowers, A/C switches
n A/C blower control units & resistors, electric control for blending flap
n Sensors
n Various sensors
n Electric drive systems
n OzonePRO professional hygienic cleaning
n EmissionPRO® emissions testing measuring instrument n LogiqPRO® software tool
n CustomerCare Portal customercare.mahle-aftermarket.com
n Website www.mahle-aftermarket.com
n Online catalog catalog.mahle-aftermarket.com
n MAHLE e-shop eshop.mahle-aftermarket.com
n Digital customer magazine mpulse.mahle.com
n mahlempulse on Instagram
n MAHLE
YouTube channel
n MAHLE Facebook page
Starter motors & alternators
Powerful and efficient—for the perfect start
E-mobility & electronics
Innovative solutions—for the mobility of the future
Workshop equipment & diagnostics
Efficient solutions—for maintenance and service