QuestionCan you tell me the best approach to removing and replacing the starter. I believe it has gone bad after initially the solenoid was sticking, became jammed out on several occasionans and now no longer responds at all.
AnswerIt's rather involved, but step-by-step:
Remove:
battery negative lead.
control module box air cooling pipe.
Remove air duct to air cleaner (ACL) housing.
Remove 4 screws holding the fan shroud and relay bracket.
Remove relay bracket and disconnect engine cooling fan (FC) connector from relay.
Turbocharged engines: Disconnect charge air hose from charge air cooler (CAC).
Remove cable from 2 clips on cover.
Disconnect vacuum hoses from cover.
Remove vacuum valve from cover.
Disassemble engine cooling fan (FC) connector.
Remove engine cooling fan (FC) with shroud.
Remove throttle pulley cover.
Turbocharged engines: Remove intermediate hose from pipe between turbocharger (TC) and charge air cooler (CAC) and hang hose to intake manifold on the throttle mechanism.
Remove plastic solenoid cover.
Remove bracket screw from engine.
Disconnect all cables from starter motor.
Remove screws holding starter motor.
Lift starter motor.
Remove nuts holding bracket.
Replacing starter motor
Install:
bracket on starter motor.
starter motor and locate 3 screws. Tighten screws to transmission to 40 Nm (30 ft.lbs.) and then bracket screw to 30 Nm (22 ft.lbs).
cables and secure plastic cover.
Note! Check that cables are correctly positioned so that there is no risk of a short-circuit.
Reinstall:
throttle pulley cover.
hoses.
Lift in engine cooling fan (FC) with shroud.
Install relay bracket and connect connector
Turbocharged engines: Install hose to charge air cooler (CAC).
Install engine cooling fan (FC) with 4 screws.
Install vacuum hoses and vacuum valve.
Install control module air cooling pipe and air duct to air cleaner (ACL) housing.
Secure wiring with clamps.
Connect battery negative lead
Start the engine a few times to check the function of the new starter motor.
