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How do i remove a starter motor out of a 98 petrol hilux and repair solenoid

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Remove the battery terminals from the battery, take a look down where the starter is and locate the two bolts holding it in and the cables going to it. Determine if its easier to undo the bolts and cables from the top or underneath the car. One cable will have a 12mm nut holding it on, and the other will be a plug in type. Remove the cables and bolts, making sure when you remove the last one that the starter is not going to drop out onto the ground. Once you remove the starter place in in a vice, gripping on one of the mounting holes or around the alloy housing where it fits into the hole on the gearbox. Be sure not to grip in on the end with the two screws and long bolts, or anywhere near there, as you could cause some damage. Remove the three 8mm bolts from the solenoid, you wil notice the cover will spring out a little. Remove the cover and you will see the plunger and two contacts. Remove the plunger simply by pulling it out, take care not to lose the long spring. Check to see if the contacts are dirty or worn down, usually one side will wear down further. Check the copper ring on the plunger and see if it is worn down. A lot of the time you can get away with just replacing the contacts and sanding the ring on the plunger with light sandpaper. Remove one of the contacts at a time, do this by undoing the nut which holds the contact in place on the stud you removed the cable from when removing the starter from the vehicle. Remove the plastic insulator and rubber o'ring (if still intact) then remove the stud and contact as one. Be sure not to lose the plastic insulator on the inside. Lightly tap the stud, holding the contact and they will separate. Fit the new contact to the stud, and leave it loosely in. Refit the contact and stud, with the insulator to the solenoid housing. Re fit the external insulator and o'ring, followed by the nut. Tighten the nut will lightly tapping the contact to keep it flat in the solenoid. Do the nut up until the stud pulls firmly into the contact.
The second contact is done in much the same way, remove the cable that goes from the solenoid to the brushes in the side of the starter by undoing the nut holding it on, then the next nut, insulator etc.. The difference is the stud does not press fit into the contact. Remove the stud first by simply pulling it out from the inside. Then slide the contact out, ensuring the paper inulsulator is retained. Be careful not to damage the connection on the inside that goes down into the solenoid. Simply fit the new contact in reverse order, and once you have just about done it up, tap it flat lightly as per the other side. Do it up completely and re-fit the cable. Fit the either cleaned or replaced plunger being sure to oil the main sliding part of it lightly,and putting a dab of grease at the pointy end. Be sure to remember to fit the spring back in. Re fit the cover with the three bolts. You can test the starter with jumper cables from a battery. Place the black cable on the alloy body of the starter, and the red cable on the free stud, where you removed the cable on the vehicle. Using a piece of wire link the small terminal where the small wire came off on the vehicle to the red cable, being sure the starter is firmly held or secured in a vice. The starter will begin to turn the instant you make the connection so don't get a fright.. haha.
Refit the starter with bolts and cables, refit the battery terminals and presto.
If the starter fails to turn when you test it, there is likely a problem with a burnt out armature inside the starter. (unless you don't hear the distinctive click of the solenoid.) If this is the case, and it makes no noise whatsoever, there is either a worn brushes inside the starter, or the pull in winding or connection is broken on the solenoid

Posted on Mar 15, 2011


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Removing starter 98 plymouth voyager 3.3

3.3L & 3.8L Engines To Remove:
  1. Disconnect and isolate the negative battery cable.
  2. Raise and safely support the vehicle.
  3. Disconnect the wiring from the starter and starter solenoid.
  4. Remove the starter mounting bolts.
  5. Remove the starter and spacer from the bellhousing.
To Install:
Starter motor removal/installation (3.3L & 3.8L engines) chry-02-33-788.gif

  1. Place starter spacer in position on bellhousing, make sure flange is toward flywheel.
  2. Place starter in position on bellhousing.
  3. Install the mounting bolts and ground wire. Tighten the bolts to 40 ft. lb. (54 Nm).
  4. Connect the wiring to the starter and solenoid.
  5. Lower vehicle.
  6. Connect the negative battery cable.
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Starter Motor —2.0L SPI Removal
sxf~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: When repairing the starter motor (11002) or performing other underhood work in the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter solenoid (11390) is electrically hot at all times. Failure to follow these instructions could result in personal injury.
  1. Disconnect the battery ground cable
  1. Remove the air cleaner outlet tube (9B659).
  1. Remove the top two starter motor bolts.

  1. Raise and support the vehicle.
  1. NOTE: A protective cap is installed over the B-terminal and must be replaced after servicing the starter motor and solenoid assembly.
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3bee1b7.gif 6. Remove the lower starter motor bolt and remove the starter motor and solenoid assembly.


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If you are looking to do this yourself, disconnect the battery negative terminal and isolate it.
Remove any covers or braces in order to access and remove the starter.
Remove the wires to the solenoid on the starter, then the bolts retaining the starter to the engine.
There may be some shims between the starter and the engine. You may need to replace these with the new starter.
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syh~us~en~file=ani_caut.gif~gen~ref.gif WARNING: When repairing the starter motor (11002) or working underhood in the vicinity of the starter motor, note the heavy gauge input lead connected to the starter solenoid (11390) is hot at all times. Make sure the protective cap is installed over the terminal and is reinstalled after repairing.
  1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
  1. Raise and support the vehicle. For additional information, refer to Section 100-02 .
  1. Remove the bolts, pin-type retainers and the front splash shield.
  1. Remove the starter solenoid terminal cover.
  1. Remove the nuts and position the starter solenoid cables aside.
  1. Remove the nut and position the starter motor ground strap aside.
  1. Remove the upper starter motor nut and stud.
  1. Remove the bolt and the starter motor.

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