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Before removing my starter today on my 1991 900S naturally aspirated/non turbo, I searched this BB and found a lot of useful information. However, after removing the starter I thought I would write procedure and add some additional notes that I discovered so that others may benefit.
PROCEDURE:
Disconnect the negative battery terminal.
Remove the 13mm nut and spade connector wires at the starter. Use a bungee cord to gently pull them down and away from the starter area.
Use a ratchet with a long extension to remove the two 12mm bolts that secure the rear starter motor bracket to the block. They are under the manifold - use a light to find them.
Remove the three upper 13mm bolts that secure the clutch cover. Wedge some small pieces of wood to gently pry open the clutch cover. This allows access to the two starter securing bolts and the upper bolt that secures the manifold bracket. Be careful not to crack the plastic dipstick tube.
Now remove the block to manifold securing bracket. It is located under the manifold and above the starter. With a 15mm open-end wrench loosen the upper bolt. You may need some leverage by placing a pipe or similar over the end of the wrench. Remove the lower bolt using a 13mm box wrench. Remove the bracket.
Remove the two starter securing nuts and bolts. Place a 15mm open-end wrench on the bolt head and loosen the bolts while holding the nut with a 17mm box wrench. It's a little tricky and a little tight but it can be done.
Now the starter should be loose. Gently but firmly pull the lower radiator hose down while pushing the rear of the starter down and towards the rear of the vehicle. The fuel supply line and the knock sensor wiring need to be between you and the starter. Push the rear of the starter in a rear and downward direction until you can slip the front of the starter towards you. It's very tight but it WILL come out.
That's all I have because I have not installed the rebuilt BOSCH starter that I purchased from a site sponsor.
Part of my struggle was figuring out what size the nuts and bolts were, so I have included this information. I hope this helps.
posted by 76.231.160...
, Thu, 23 Jan 2014 18:21:55
, Fri, 24 Jan 2014 06:38:10
, Fri, 24 Jan 2014 10:23:45
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