STARTER MOTOR REPLACEMENT

A pain of a job the first time I did it, now I can do this from start to finish in 40 minutes! That should give you a clue how often I have done it! The starter isn't the easiest to reach on a 200Tdi (if you can't see it, its under the turbo!), but here's how I do it.

1. Push the bonnet back (remove "R" pin on bonnet stay), remove exhaust down pipe.

2. Remove air filter housing and move washer bottle to one side (2x 10mm head nuts) for easier access.

3. Disconnect battery, otherwise you WILL get a spark!

4. Remove lower starter nut from below under the car.

5. Remove top two bolts (13mm heads) from above. You can see the one nearest the passenger wing if you look from where the washer bottle was. The inner one can be seen if you look down from the now upright bonnet towards the back of the bulkhead / bell housing area. I reach these with your typical 8 or 9 inch extension bar so your ratchet is clear of the end of the starter.

6. I then withdraw the starter partially and now remove the wiring to the solenoid on the back of it, I find this way easier.

7. "Wiggle" a little and remove starter from the top.

This picture is the flywheel ring-gear taken from where the washer bottle would have sat on the inner wing, the hole is obviously where the starter bolts in to, I have marked where the three bolt holes / stud is in yellow (if you could see them).

8. According to the Hayes book of lies, replacement is the reverse of removal. In this case they are actually right....

Good Luck, it's not actually very difficult, just awkward to reach.

home