Starter Motor: Service and Repair

This procedure is for "New Starter # 9162618-4" as per T.S.B. # 3-33-801

Removing starter motor
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.

Installing Starter Motor
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.