Sprinter 2005-2007

Starter

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Removal & Installation



2.7L Engine

The starter motor and solenoid assembly is located at the left/rear side of engine.

  1. Disconnect and isolate negative battery cable.
  2.  
  3. Working from under vehicle hood, remove bolt retaining wiring trough to transmission bellhousing.
  4.  
  5. Working from under vehicle hood cut necessary nylon; wiring trough tie-wraps near starter motor. Temporarily position wiring harness trough for access to starter.
  6.  
  7. Working from under vehicle hood, remove 2 starter solenoid wiring harness nuts.
  8.  
  9. Remove solenoid wire connector from solenoid stud, and battery cable from solenoid stud.
  10.  
  11. Raise and support vehicle.
  12.  
  13. Remove 2 starter mounting bolts (E14Torx).
  14.  
  15. Remove starter from transmission bellhousing.
  16.  

To install:

  1. Raise and support vehicle.
  2.  
  3. Position starter motor to transmission housing.
  4.  
  5. Install 2 mounting bolts.
  6.  
  7. Lower vehicle.
  8.  
  9. Connect battery cable and solenoid wiring to solenoid (2 nuts).
  10.  
  11. Position wiring harness trough and install retaining bolt.
  12.  
  13. Install new nylon tie-wraps to wiring trough.
  14.  
  15. Connect negative battery cable.
  16.  

3.0L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the engine undercover.
  6.  
  7. Remove the bolt securing the starter wiring harness retainer bracket to the transmission bellhousing.
  8.  
  9. Disconnect the battery positive cables and the starter solenoid wire from the starter solenoid.
  10.  
  11. Remove the starter mounting bolts.
  12.  
  13. Remove the starter from transmission bellhousing.
  14.  

To install:

  1. Positing the starter to the transmission bellhousing and tighten the mounting bolts to 30 ft. lbs. (40 Nm).
  2.  
  3. Connect the battery cable and solenoid wiring to the solenoid and tighten the nut to 10 ft. lbs. (14 Nm).
  4.  
  5. Position the wiring harness retainer bracket and install retaining bolt.
  6.  
  7. Lower the vehicle.
  8.  
  9. Connect the negative battery cable.
  10.  

Testing & Troubleshooting



Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Starter Specifications for specifications.

  1. Remove starter motor from vehicle.
  2.  
  3. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
  4.  
  5. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
  6.  
  7. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications.
  8.  
  9. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications.
  10.  
  11. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly.
  12.  

Starter Solenoid

This test can only be performed with starter motor removed from vehicle.

  1. Remove starter motor from vehicle.
  2.  
  3. Disconnect wire from solenoid field coil terminal.
  4.  
  5. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to the next step. If not OK, replace faulty starter motor assembly.
  6.  
  7. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly
  8.  

 
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