Starter Motor - Revised

SECTION
3

GROUP
33

NO.
801

DATE
July 1996

New starter motor for 850
850 1997-

REFERENCE: TP 0007201, Section 0(00), New Car Feature 1997 850

New starter motor for 850

A new starter motor with new P/N 9162618-4 has been introduced for the 850. The change affects all 850 engine variants (B52xx).

AA1

A new lighter starter motor P/N 9162618-4 has been introduced from model year 1997. The replacement of the starter motor is described in the following.

AA2





Removing starter motor

Remove:

- battery negative lead.

- control module box air cooling pipe.

AA3

Removing starter motor, continued





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.

AA4

Removing starter motor, continued





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.

AA5

Removing starter motor, continued





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.

AA6





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.

AA7

Installing starter motor

Reinstall:





- throttle pulley cover.

- hoses.

AA8

Installing starter motor, continued





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.

WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01

Operation No. Labor description Time allowance

33118-2 Starter motor, replace non-turbo 0.7 hr
turbo 1.0 hr