Starter Motor: Service and Repair

Remove Starter, Install

Shown On Model 203:

DANGER:
Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury with caustic burns to eyes and skin from battery electrolyte or from handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking.
- Wear acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.

1 Disconnect ground cable of battery

DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.

2 Raise vehicle.
3 Remove front and rear engine compartment paneling from below
4 Completely remove exhaust system
5 Dismount exhaust shielding plate (1) for propeller shaft front axle gear

Collar bolt of mounting carrier at front axle gear and engine mount carrier - 22 N.m

6 Detach mounting clamp (2) for electrical line terminal 50 (5) at choke housing

7 Detach cap (4) from terminal 50
8 Unscrew nut of electrical line (5) from terminal 50 at starter

Nut of Connection Circuit 50 - 6 N.m

9 Unscrew nut of electrical line (3) from terminal 30 at starter

Nut of Connection of Circuit 30 - 14 N.m

10 Dismount starter (M1)

Bolt of Starter to Crankcase(6) - 42 N.m

11 Take out starter (M1) toward rear via the rack-and-pinion steering
12 Install in the reverse order
13 Perform basic programming
14 Read out fault memory with STAR DIAGNOSIS and erase if necessary