The starter solenoid (magnetic switch) is an integral part of the starter assembly.
- Remove the starter from the van. Remove the heat insulator from the starter
assembly, if equipped.
- Disconnect the wire lead from the magnetic switch terminal.
- Remove the two long, through bolts holding the field frame to the magnetic
switch. Pull out the field frame with the armature from the magnetic switch.
- Toseparate the starter housing from the magnetic switch assembly, remove
the two screws and the starter housing with the pinion gear (1.6 kW), idler
and clutch assembly.
To install:
- If necessary, install the gears and clutch assembly to the starter housing.
Apply grease to the gear and clutch assemblies and place the clutch assembly,
idler gear, bearing and pinion gear (1.6 kW) in the starter housing.
- Insert the spring into the clutch shaft hole and place the starter housing
onto the magnetic switch. Install the two screws.
- Install the field frame with the armature onto the magnetic switch assembly
and install the two through bolts. Tighten the bolts on the 1.4 kW to 52 inch
lbs. (6 Nm) and on the 1.6 kW to 82 inch lbs. (9 Nm).
NOTE: There is a protrusion or tab on each part; make sure
you line them up correctly during assembly.
- Connect the wire to the terminal on the magnetic switch and tighten the
nut to 52 inch lbs. (6 Nm). Install the heat insulator, if equipped.
- Reinstall the starter on the vehicle. Check starter system for proper operation.
