Had issues starting recently culminating in not being able to start at all and getting a bump start from the AA man... I thought initially that the problem was likely a run down battery and even though my old one was only 2 years old, I bought a new one as it didn't seem to be charging up very well with the charger. Anyway new battery installed and still not wanting to start - sometimes the starter just clicked other than that it might just try and start very slowly, but would eventually start. Then back to square one where the starter no longer turns and just clicks - at this point the AA man was summonsed to bump start me so I could get home. As a result I have decided on new starter motor which hopefully I will fit myself, even though it looks a bit awkward... I've consulted the Haynes and Bentley manuals neither of which were a great deal of help, however the Muir book does explain the removal and instalment much better. I do though want to confirm my understanding of what is involved. My main query is about the top retaining bolt: I get that it goes through the gear box housing through into the engine bay and by my reckoning it should be retained in the engine bay by a nut, which when you look at the bell housing is at the 2 o'clock position...? Now, Muir describes loosening this nut until the bolt starts to move, clamping the nut with mole grips so that it cannot move while continuing to remove it from under the van by unbolting it using the 17mm socket until eventually the mole grip falls in the engine bay and the bolt comes out completely. Now looking at the bolt from the top of the starter, it does not have a proper bolt head, and I don't understand why I could not completely remove the bolt inside the engine bay then effectively push this bolt out the other side pulling it through from underneath the van. I am presuming that it must be threaded through the aperture of the gear box housing? Would a socket work on this unusual head to help remove it from the underside? The bottom nut appears much simpler that is indeed a normal nut to be unbolted. Once these are removed it should be a case of pull the old one out from the gearbox and push new one in then reconnect the bolts and wiring appropriately? Cheers Pete
If you have a type 1 engine its a bit of a reach around Its easier using a ratchet spanner, the bolt is a D bolt of should be so in theory will be semi locked in place by the starter motor, if you replace the starter motor you need to do the brass bush as well thet goes into the bell housing. Have you checked its not ignition switch related ?
Mi Mick, Luckily I have a Type 4 engine so the bell housing is easily seen and accessible.... I had decided on it not being the ignition switch itself at fault a I can hear the click from the solenoid and in the earlier stages of this issue the starter did turn but very slowly. I know last time I had a similar issue the connections at the solenoid were possibly at fault but I can't see anything wrong there this time...
Simple then disconnect - battery terminal, Remove the main cable on the starter, remove the spade connection, just undo the D bolt nut, undo the bottom one and pull the starter off, Swap bush and put it back in reverse
I know this sounds like a daft question, but just getting this straight in my head: So if I undo the D bolt nut inside the engine bay and remove it completely, that bolt should theoretically gust push through from the engine bay and be able to be pulled out from underneath the van ? I have new bush too!
Yes it might not push out as thats the idea of the D bit to lock it in the starter motor so you can do it on your own and someone does not have to hold the other end of the bolt. Just undo them both and pull the starter and the D bolt will come with it.
Cool, thanks for that You know when something just seems too easy to be true .....? You've confirmed what I was hoping was the right way to do this....
the new bush may need soaking in oil overnight and removing the old one may be challenging, and don't test the new starter on the bench as the drive dog end would not be supported. as said, the earth strap connections should be cleaned back to bright metal, they are often overlooked.
Yes worth a check.....when I cleaned bolt hole areas and fitted a new gearbox earth strap my starting was much improved. Don't bother with a repro original type (they are too short) just fit a modern new strap.
Oil lite bush is pre-impregnated with oil . Sounds to me like you need a hot start relay and not a new starter motor ...but you could be right . You will need a M12 Tap to remove bush
The other thing is the D bolt can be a pain to keep pressed through the bellhousing on the way back in. A trick I have used is to wedge it in the recess in the top of the starter with an offcut of rubber pipe of the right length. Then when you put the nut on, the D bolt cannot slide forward out of reach from the engine bay..
I did what @SundialCamperSpecialists recommended and held it in place with a lump hammer. Just don’t forget you’ve put it there and spend 3 weeks wondering where it is!
Thats the advantage of the rubber pipe. Its too short to use for anything else and on one occasion I found it still in place the next time I pulled the engine.
I had similar issues with starters on my 2000c type 4 and ended up getting the original stater motor refurbished as I didn't rate the newer ones. I would suggest really checking the earth strap is 100% like other have said as that can cause such issues. Another thing I had to do with my bus was sometime put it in 1st or 2nd and rock it to get the starter in the right place to give it a proper kick but I never got to the bottom of why I needed to do that every so often Finally, be super careful when swapping the bushes if you do it yourself as if it drops you will have to drop the engine etc I think to retrieve it!
