Remove starter motor

REMOVAL & INSTALLATION

Fig. Remove the starter electrical connections, noting their locations

Fig. Location of the two starter retaining bolts

1. Disconnect the negative battery cable.
2. Detach the air-flow sensor assembly connector and remove the breather hose.
3. Remove the resonator retaining nuts and remove the air intake hose and resonator assembly as required.

1. If equipped with Active-ECS suspension, remove the air compressor as follows:

1. Detach the two electrical connectors, from the compressor.
2. Disconnect the air line at the compressor.
3. Remove the three mounting bolts, securing the compressor to the chassis.

1. Raise the vehicle and support safely.
2. Remove the engine undercover.
3. Remove the heat shield from beneath the intake manifold on the 1.5L engine.
4. If necessary, detach the speedometer cable connector at the transaxle end.
5. Detach the starter motor electrical connections.
6. Remove the starter motor mounting bolts and remove the starter.
7. The installation is the reverse of the removal procedure. Tighten the starter mounting bolts to 22 ft. lbs. (31 Nm).
8. Connect the negative battery cable and check the starter for proper operation.

1. Disconnect the negative battery cable at the battery.
2. Detach the air inlet duct from the throttle body.
3. Position a drain pan under the oil filter, then remove the oil filter.
4. Remove the top starter bolt.
5. Raise and safely support the vehicle.
6. Remove the lower starter retaining bolt.
7. If necessary, position the engine wiring harness aside.
8. Position the starter to enable access to the solenoid wiring, then detach the wiring.
9. Remove the starter from the vehicle. To install:
   
10. Raise the starter to the vehicle, then attach the wiring.
11. Position the starter, then secure using the lower starter bolt. Tighten to 66 ft. lbs. (90 Nm). Fig. 1: When installing the starter on the 2.4L engine, tighten the mounting bolts to 66 ft. lbs. (90 Nm)
    
    
12. If moved, reposition the engine wiring harness.
13. Attach the solenoid electrical connectors.
14. Carefully lower the vehicle.
15. Install the top starter bolt, then tighten to 66 ft. lbs. (90 Nm).
16. Replace the oil filter.
17. Fasten the air inlet duct to the throttle body.
18. Connect the negative battery cable.
19. Check the oil level and add if necessary.
20. Start the engine, recheck the oil level and add if necessary.

1. Disconnect the negative battery cable.
2. Raise and safely support the front of the vehicle securely on jackstands.
3. Remove the lower closeout panel.
4. Remove the electrical leads. Fig. 2: Two electrical leads connect to the starter solenoid. The larger one has battery power as long as the battery is connected. The smaller one only has power when the key is turned to START
   
   
5. Remove the starter motor to engine bolts, then remove the starter from the vehicle. To install:
   
6. Install the starter. Position one engine-to-starter bolt in the lower bolt hole, then finger-start the bolt.
7. Connect the electrical leads to the starter. Tighten the cable to the solenoid to 106 inch lbs. (12 Nm).
8. Install the starter-to-engine bolts and tighten to 37 ft. lbs. (50 Nm)
9. Install the lower closeout panel.
10. Lower the vehicle.
11. Connect the negative battery cable.

• First unplug the negative cable of your car battery for safety reasons.
• Then remove the 10 bolts underneath the front of the vehicle to remove the splash guard. There are five bolts in the front, three in the center and two on each side.
• Remove the electrical connectors attached to the starter motor. They are connected by tabs and can be easily removed with your hands.
• You can use the socket wrench to remove the bolts to loosen starter motor. The starter motor will slip right off as the screws are removed.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. If necessary for access, remove the splash shield.
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
5. Label and detach the electrical connectors from the starter.

1. It may allow more room it you remove the right side cooling fan.
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 32 ft. lbs. (43 Nm).
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
4. If removed, install the splash shield.
5. Carefully lower the vehicle.
6. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Raise and support the vehicle safely.
3. If necessary for access, remove the splash shield.
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
5. Label and detach the electrical connectors from the starter.
   

1. It may allow more room it you remove the right side cooling fan.
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 32 ft. lbs. (43 Nm).
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
   
1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
   


3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
4. If removed, install the splash shield.
5. Carefully lower the vehicle.
6. Connect the negative battery cable.

1. Remove or disconnect the following:
   Negative battery cable Front exhaust pipe, if necessary for access Starter heat shield, if equipped Brace rod from the front of the engine and the bell housing Drivers side wheel to access the starter motor wires and the starter motor attaching bracket-to-engine bolt through the opening in the wheel well Wires from the starter solenoid Attaching bracket-to-engine mount bolt Starter-to-engine block bolts. When removing the last bolt, be sure to support the starter to keep it from falling and possibly injuring you. Starter and shims (if equipped) from the vehicle Bracket from the starter assembly, if equipped
   
   
   
   Fig. Starter motor and related components - 2.2L engine
   
   

1. Install or connect the following:
   Bracket to the starter, if removed. Tighten the bracket nuts to 97 inch lbs. (11 Nm). Starter and shims (if equipped) into position in the vehicle and thread one of the retaining bolts to hold it in position. Bracket-to-engine mount bolt (loosely), if equipped Starter mounting bolt, then tighten all mounting fasteners to 32 ft. lbs. (43 Nm) Wiring to the solenoid Brace rod and tighten the retainers Front exhaust pipe and tighten the fasteners, if removed Starter heat shield, if equipped Driver-s side wheel, if removed Negative battery cable

1. Disconnect the negative battery cable.
   
2. Raise and support the vehicle safely.
   
3. If necessary for access, remove the splash shield.
   
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
   
5. Label and detach the electrical connectors from the starter.
   

2. It may allow more room it you remove the right side cooling fan.
   
4. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.
   

1. Place the starter in position, then install the starter-to-engine bolts and tighten to 1 ft. lbs. (43 Nm).
   
2. Attach the electrical connectors to the starter, as tagged during removal. Tighten as follows:
   
   1. Tighten the nut on the solenoid battery terminal to 12 ft. lbs. (16 Nm).
      
   2. On the SD-250 and SD-255 models, tighten the nut on the "S" terminal to 22 inch lbs. (2.5 Nm).
      
3. If removed, install the flywheel inspection cover and secure with the retaining bolts. Tighten the flywheel cover bolts to 62 inch lbs. (7 Nm).
   
4. If removed, install the splash shield.
   
5. Carefully lower the vehicle.
   
6. Connect the negative battery cable.
   

1. Disconnect the negative battery cable.
   
2. Raise and support the vehicle safely.
   
3. If necessary for access, remove the splash shield.
   
4. If equipped, unfasten the flywheel inspection cover bolts and remove the cover.
   
5. Label and detach the electrical connectors from the starter.
   

Exploded view of the starter motor electrical connections
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1. It may allow more room it you remove the right side cooling fan.
   
2. Remove the starter-to-engine bolts, then carefully lower the starter from the vehicle.
   

Unfasten the front mounting bolt (1) and remove any necessary shims (2), noting their locations for installation
Click to Enlarge