OK, As promised ...
Stripped the Starter out of the bike,
Went quite well, I have wobble extensions, so they give just enough movement to deal with the back fixing
I had more trouble getting the motor out of the frame than i did with the bolt lol
Observation 1
Starter is a Valeo unit ...
According to the OEM catalogue , the Valeo unit wasn't fitted to pre MY08 bikes.
Up to MY08 was a Bosch unit
Hmm makes me wonder did they change the starter in an attempt to cure the hot start issue??
OK unit out and on the bench,
<a href="http://s16.photobucket.com/user/mart360/media/Bendix%20business%20end.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Bendix%20business%20end.jpg" border="0" alt="Business end bendix pre strip photo Bendix business end.jpg"/></a>
Hmm not looking to hot i have to say
Business end & bendix
<a href="http://s16.photobucket.com/user/mart360/media/Bendix%20business%20end.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Bendix%20business%20end.jpg" border="0" alt="Business end bendix pre strip photo Bendix business end.jpg"/></a>
Pretty grimey, and the bendix looks poor
Bendix - stripped out
<a href="http://s16.photobucket.com/user/mart360/media/Bendix%20stripped.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Bendix%20stripped.jpg" border="0" alt="Bendix stripped photo Bendix stripped.jpg"/></a>
The one way clutch works, but i's still a bit stiff to turn by hand
Gearbox original grease
<a href="http://s16.photobucket.com/user/mart360/media/Gearbox%20pre%20strip.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Gearbox%20pre%20strip.jpg" border="0" alt="Gearbox - original grease photo Gearbox pre strip.jpg"/></a>
Looks well worn in, need to get shot of that lot then !
Field coils
<a href="http://s16.photobucket.com/user/mart360/media/Field%20colis.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Field%20colis.jpg" border="0" alt=" photo Field colis.jpg"/></a>
They dont look to hot either!
Gearbox degreased ...
<a href="http://s16.photobucket.com/user/mart360/media/Gearbox%20degreased.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Gearbox%20degreased.jpg" border="0" alt=" photo Gearbox degreased.jpg"/></a>
Now to rebuild
Gearbox with fresh moly
<a href="http://s16.photobucket.com/user/mart360/media/Gearbox%20moly%20packed.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Gearbox%20moly%20packed.jpg" border="0" alt="Gears moly greased photo Gearbox moly packed.jpg"/></a>
Bendix cleaned, lubed, and reassembled
<a href="http://s16.photobucket.com/user/mart360/media/Bendix%20reworked.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Bendix%20reworked.jpg" border="0" alt="Bendix cleaned & reassembled photo Bendix reworked.jpg"/></a>
Fitting the brush pack 1
Be quick
<a href="http://s16.photobucket.com/user/mart360/media/Fitting%20brush%20pack%201.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Fitting%20brush%20pack%201.jpg" border="0" alt="Fitting brushpack 1 photo Fitting brush pack 1.jpg"/></a>
Done .. took seconds, no special tools needed
I'll show you why & how
Valeo Commutator 1
<a href="http://s16.photobucket.com/user/mart360/media/Communtator%20cleaned.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Communtator%20cleaned.jpg" border="0" alt="Communator photo Communtator cleaned.jpg"/></a>
Commutator 2
<a href="http://s16.photobucket.com/user/mart360/media/Fitting%20brush%20pack%202.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Fitting%20brush%20pack%202.jpg" border="0" alt=" photo Fitting brush pack 2.jpg"/></a>
Got to say its a clever way of doing things ....
Be warned, if you split the brush pack, it needs a nack to get it back together ... not to difficult though
All done
<a href="http://s16.photobucket.com/user/mart360/media/Rebuilt.jpg.html" target="_blank"><img src="http://i16.photobucket.com/albums/b30/mart360/Rebuilt.jpg" border="0" alt="Finished photo Rebuilt.jpg"/></a>
So battery is on charge,
Will refit and hava a go tommorow morning ...
I fould a place in poland that did the brush pack. £20 odd delivered ... I have one ordered just in case.
Of note the starter 9D6G is used in multiple applications
AUDI A3 1.4 TFSi, A3 1.6, A3 1.6 FSi, A3 1.6 FSi Sportback, A3 1.6 Sportback, A3 1.8 TFSi, A3 1.8 TFSi Quattro, A3 1.8 TFSi Sportback, A3 2.0 FSi, A3 2.0 FSi Sportback, A3 2.0 TFSi, A3 2.0 TFSi Quattro, A3 2.0 TFSi Sportback, A3 2.0 TFSi Sportback Quattro, S3 2.0 TFSi Quattro, TT 1.8 TFSi, TT 2.0 TFSi, TT 2.0 TFSi Quattro, TT 2.5 TFSi Quattro
SEAT Altea 1.4, Altea 1.4 16V, Altea 1.4 TSi, Altea 1.6, Altea 1.6 Multifuel, Altea 1.6 XL, Altea 1.8 TFSi, Altea 1.8 TFSi XL, Altea 2.0 FSi, Altea 2.0 FSi XL, Cordoba 1.2 12V, Cordoba 1.4 16V, Cordoba 1.6, Cordoba 1.6 16V, Cordoba 2.0, Ibiza 1.2, Ibiza 1.2 12V, Ibiza 1.4, Ibiza 1.4 16V, Ibiza 1.6, Ibiza 1.6 16V, Ibiza 1.6 Sports Coupe, Ibiza 1.8 Turbo Cupra R, Ibiza 2.0, Leon 1.4 16V, Leon 1.6, Leon 1.6 16V, Leon 1.8 TSi, Leon 2.0 FSi, Toledo 1.6, Toledo 1.8 TFSi, Toledo 2.0 FSi
SKODA Fabia 1.2, Fabia 1.2 Pralails, Fabia 1.4, Fabia 1.4 16V, Fabia 1.6, Octavia 1.4, Octavia 1.4 TSI, Octavia 1.6, Octavia 1.6 FSi, Octavia 1.8 TSi, Octavia 2.0 FSi, Octavia 2.0 FSi 4x4, Octavia 2.0 RS, Roomster 1.2, Roomster 1.4, Roomster 1.4 TDi, Superb 1.4 TSI, Superb 1.8 TSI
VOLKSWAGEN EOS Eos 1.4 TSi, EOS 2.0 FSi, EOS 2.0 TFSi, Golf IV 1.6 FSi, Golf V 1.4, Golf V 1.4 16V, Golf V 1.4 16V Plus, Golf V 1.4 FSi, Golf V 1.4 FSi Plus, Golf V 1.4 TSI, Golf V 1.4 TSI Plus, Golf V 1.6, Golf V 1.6 FSi, Golf V 1.6 Plus, Golf V 1.6 Plus Multifuel, Golf V 2.0, Golf V 2.0 FSi, Golf V 2.0 FSi 4 Motion, Golf V 2.0 FSi Plus, Golf V 2.0 GTi, Golf VI 1.4, Golf VI 1.4 TSI, Golf VI 1.6, Golf VI 1.6 BiFuel, Golf VI 2.0 TSi, Jetta 1.6, Jetta 1.6 FSi, Jetta 2.0 FSi, Jetta 2.0 TFSi, Jetta 2.5, Multivan 2.0, New Beetle 2.5 Turbo, Passat 1.4 TSI, Passat 1.4 TSi EcoFuel, Passat 1.6 FSi, Passat 1.8 TSI, Passat 2.0 FSi, Passat 2.0 FSi 4 Motion, Passat 2.0 TFSi, Passat 2.0 TSi CC, Polo 1.2, Polo 1.4, Polo 1.4 16V, Polo 1.6 16V, Polo 1.8 GTi, Polo 1.8 GTi Cup Edition, Scirocco 1.4 TSi, Tiguan 1.4 TSi, Tiguan 2.0TFSi, Touran 1.4 TSi EcoFuel, Touran 1.6, Touran 1.6 FSi, Touran 2.0 FSi
So if you need one to test, the above units use the same brush pack.
Will let you know how i get on it the morning
M art