1) Review any additional information sheets
2) Remove negative battery cable. This prevents accidental shorts during starter replacement.
3) Charge and load test battery. A weak or defective battery will cause starting problems.
4) Remove wire connections from old starter motor. Make a note of each connection for the new starter installation.
5) Remove fixing bolts.
6) Remove old starter motor and check condition of starter motor
7) Check new starter
Sometimes starters of different original brands are fitted on one particular type of car. In spite of the external difference, they are the same in terms of capacity, installation and connection. The reference numbers of these various manufacturers are included in the conversion list in Remy catalogue.
8) Install new starter motor
DOWEL BUSHING
Install bushing if old starter motor is provided with this bushing.
Damaged or deformed bushes should be replaced by a new one which is needed for a good alignment of the starter motor. Be careful that the old bushing does not stay in the motorblock.
OPEN SHAFT UNITS (VW – Audi)
New bush to be fitted in motorblock
FIXING BOLTS
Tighten fixing bolts evenly to prevent bad alignment of the starter motor with the flywheel.
9) Check installation
Inspect wiring, connections and fuse links for worn insulation, breaks or corrosion. Repair broken or damaged connections. Make sure all wires have been connected correctly and there are no pinched wires or shorts to ground. Check and clean battery cable connections at battery, framelchassis and engine block. Avoid breaking the plastic solenoid cap by carelessness or over-tightening of the battery cable.
10) Connect negative battery cable LAST
11) Start engine
Check voltage on solenoid contact 50 (key contact) during starting. This should be minimum 9,5 Volt. If necessary the voltage can be increased by installing an auxiliary solenoid (see diagram). The “click-click” noise when starting usually indicates this shortage of voltage.
12) Double check your work. STOP engine and recheck fixing bolts and wire connections.
1) Review any additional technical bulletins supplied with this unit
2) Remove negative battery cable This prevents accidental shorts during alternator replacement.
3) Charge and load test battery. A weak or defective battery will damage your new alternator.
4) Remove wire connections from old alternator. Make a note of each connection for the new alternator installation.
5) Remove old alternator
MANUAL BELT TENSIONERS
Remove adjusting ear bolt. Remove belt(s). Then, remove pivot bolt.
AUTOMATIC TENSIONERS
Remove belt first using proper tool to relieve belt tension. Belt will slip off. Remove mounting bolts. Save hardware for installation of new unit.
6) Make sure the pulley on the new and old unit match. If necessary, exchange pulleys, noting spacer and washer locations. NEVER use V belts on serpentine pulleys or serpentine belts on V- pulleys. Always count the grooves in serpentine pulleys to assure an exact match. If you change the pulley, use a torkque ranch and a ring spanner to ensure pulley nut is tight.
7) Install new starter motor
INSPECT BELTS
Inspect belts for wear, cracks and glazing and replace, if necessary. On some vehicles, it may be easier to attach wiring before attaching mounting bolts. Do not overtighten electrical connections.
MANUAL TENSIONING
Alternators - Installation
Install mounting bolts loosely so belt can be adjusted. Position belts on pulleys. Apply leverage to alternator front housing only (end closest to pulley) until belt tension meets vehicle specifications. Tighten mounting bolts. Typically, belts will deflect approx. 3/8” to 1/2” when pressed midway between the two farthest pulleys. The tension on a new V-belt should be checked and reset after 15 minutes of operation.
AUTOMATIC TENSIONS
Install all alternator mounting bolts finger tight. Use proper tool to release tension and route belt around pulleys. Allow tensioner to tighten belt.
8) Check installation
Inspect wiring, connections and fuse links for worn insulation, breaks or corrosion. Repair broken or damaged connections. Make sure all wires have been connected correctly and there are no pinched wires or shorts to earth. Check and clean battery cable connections at battery, frame/chassis and engine block.
9) Connect negative battery cable last
10) Start engine
Check charging system light or gauge on instrument panel for proper system operation. Let engine idle for 10 minutes to allow voltage to stabilize. Refer to troubleshooting section if you have any problems or want to perform more detailed system tests.
DO NOT DISCONNECT ANY WIRING WHILST ENGINE IS RUNNING
11) Double check your work
STOP engine, verify belt tension and recheck mounting bolts.