Starter Motor: Service and Repair
Starter motor, replacing
Special tools:
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
951 2955 Cover 951 2955 Cover
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Note! Lift the vehicle according to: Jacking points, body Service and Repair.
Removing the upper cross stay
Remove:
- the 4 screws at the suspension turrets
- the screws of the upper engine mount on the engine
- the upper cross stay.
Removing components
Remove:
- the battery negative cable. See: Battery, disconnecting Battery Disconnecting.
- the expansion tank cap.
Raise the vehicle.
Removing the protective plate (skid plate)
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Remove the 6 screws.
Lift and slide the protective plate forward.
Remove the protective plate.
Draining coolant
Open the cock on the lower left edge of the radiator.
Drain the coolant into a clean receptacle.
Close the cock.
Installing the protective plate
Install:
- the protective plate
- the 6 screws; tighten.
Lower the vehicle.
Removing the air cleaner cover
Remove the air cleaner cover by pulling it straight up.
Removing connectors
Remove:
- the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness
- the connector from the mass air flow sensor.
Removing the air cleaner (ACL)
Remove:
- the 2 screws of the fresh air hose in the front plate
- the fresh air hose
- the hose clips of the intake manifold between the mass air flow sensor and the electronic throttle module (ETM)
- the air cleaner by pulling it straight up.
Removing the vacuum hoses
Remove:
- the connector to the brake vacuum valve
- the vacuum hose from the vacuum pump by pressing in the quick-action lock
- the vacuum hose from the brake vacuum valve
- the vacuum hose from the intake manifold
- the brake vacuum from the retainer.
Removing the radiator hoses
Detach the radiator hoses at the quick-release coupling toward the firewall.
Detach the coolant hose from the throttle body by undoing the clamp.
Bend aside the coolant hoses.
Removing the lines
Remove:
- the connector to the electronic throttle module (ETM) and the electrical distribution center
- the protective cap from the starter motor solenoid
- the nut of the positive leads on the starter motor solenoid
- the positive leads
- the control current lead from the starter motor solenoid.
Removing the upper engine mount
Remove:
- the 4 screws
- the upper engine mount.
Removing the EVAP valve bracket
Remove:
- the EVAP valve from the bracket
- the line from the EVAP valve to the tank by releasing the quick-action lock
- the hose from the intake manifold to the EVAP valve by releasing the hose clip
- the 2 screws of the EVAP valve bracket
- the EVAP valve bracket.
Removing the lifting eye
Remove:
- the 3 screws of the lifting eye
- the lifting eye.
Removing the coolant hose clamp
Open the hose clip and move it to the side.
Removing the coolant connection pipe
Remove:
- the 2 screws
- the connection pipe. Scrap the gasket.
Removing the starter motor
Remove:
- the 2 screws
- the starter motor.
Installation
Note! For tightening torques, see: [1][2]Specifications
Installing the starter motor
Install:
- the starter motor.
- the 2 screws; tighten.
Installing the coolant connection pipe
Install:
- a new gasket
- the connection pipe on the coolant hose
- the 2 screws; tighten.
Installing the clamp on the coolant hose
Fit the clamp in its original position.
Installing the lifting eye
Install:
- the lifting eye at the connection pipe
- the 3 screws; tighten
- the cable stem in the clip.
Installing the EVAP valve bracket
Install:
- the EVAP valve bracket
- the 2 screws of the bracket; tighten
- the hose from the intake manifold to the EVAP valve; secure with the clamp
- the line to the tank on the EVAP valve; secure with the quick-action lock
- the EVAP valve on the bracket.
Installing the upper engine mount
Install:
- the upper engine mount.
- the 4 screws; tighten.
Installing the leads
Install:
- the connector to the electronic throttle module (ETM) and the electrical distribution center
- the positive leads, x 2, on the solenoid. Tighten in accordance with: Tightening Torque
- the nut; tighten
- the protective cover on the nut
- the control current lead on the solenoid.
Installing the coolant hoses
Install:
- the 2 coolant hoses on the connections at the firewall; secure with the quick-action lock
- the coolant hose on the throttle body; secure with the clamp.
Installing the air cleaner (ACL)
Install:
- the air cleaner on the left frame member
- the intake hose on the throttle body; secure with the clamp
- the connector to the mass air flow sensor.
Installing vacuum hoses
Install:
- the vacuum hose to the vacuum pump; secure with the quick-action lock
- the vacuum hose on the brake vacuum valve
- the vacuum hose on the intake manifold; secure with the clamp
- the brake vacuum valve in the retainer
- the connector to the brake vacuum valve.
Installing the fresh air intake manifold
Install:
- the intake manifold
- the 2 screws.
Installing the engine control module (ECM) connectors
Install:
- the connectors to the engine control module (ECM); secure with quick-action lock
- the cover over the air cleaner.
Installing the upper cross stay
Install:
- the cross stay between the suspension turrets
- the 4 screws in the suspension turrets; tighten
- the screw of the cross stay mount on the upper engine mount; tighten.
Check
Caution! Make sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.
Fill with coolant using filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover: 951 2955 Cover 951 2955 Cover.
Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluid as necessary.