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(331-2628) Starter motor does not work

Symptom: Starter motor does not work.

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 331-2628
Date: ........... Oktober 2006
Market: all
Starter motor does not work

Cars affected

9-3 M03-04 with engine alternative B207

Background

The positive cable connection to the starter motor and the generator is not waterproof. This may result in water entering and rusting away the connection.

In the case of customer complaint, the following procedure must be carried out.

Symptom description

Starter motor does not work.



Parts required

55 563 382 Positive cable 25 mm, cold climate market

55 563 072 Positive cable 16 mm, hot climate market

92 150 191 Cable tie (x 13)

Heat resistant fabric tape

Procedure


1. Position the car on a lift.

2. Remove the upper engine cover (A).


3. Remove the battery cover, lower section in accordance with WIS - Electrical System - Charging systems - Adjustment/Replacement

4. Remove the positive cable connection (A) from the positive terminal for the battery.


5. Raise the car.

6. Remove the positive cable connection (A) from the starter motor.


7. Lower the car.

8. Remove the positive cable connection (A) from the generator. Insulate the positive cable connection using heat resistant fabric tape.


9. Remove the electrical centre:


• Remove the electrical centre's cover (A).

• Remove the lower section of the electrical centre (B).

• Remove the tape (C).

• Remove the cable tie (D).

10. Remove the fuses (A) and the positive connections (B) in the electrical centre (342):

Note

There may be a cable/fuse missing depending on the car's specification.



• Remove fuse 1-4.

• Remove the positive connections to fuse 1-4.

• Cut the cables for the positive connections in front of the seal (C) on the wiring harness.

Note

The cable to fuse 2 is brown/white and to fuse 3 blue/white. Both corresponding cables in the extension wiring are brown/white.


11. Cut the positive cable that runs to the battery and insulate:


• Cut the positive cable's casing (A) between the electrical centre and the lamp.

• Cut the positive cable (B) so that the positive cable protrudes approx. 10 mm from the casing.

• Insulate the positive cable using heat resistant protective tape.

• Seal the casing and the positive cable using heat resistant fabric tape so that water cannot enter.

12. Fit the extension wiring:


• Fit the positive cable connection to the battery's positive terminal (A).

• Insert the positive connections into the electrical centre through the seal (B).

• Route the extension wiring along the engine's wiring and allow the extension wiring to hang down.

13. Fit the positive connections (A) and the fuses (B) in the electrical centre:

Note

There may be a cable/fuse missing depending on the car's specification.



• Connect the red cable to fuse 1.

• Connect the brown/white cable to fuse 2.

Note

Which brown/white cable is connected to fuse 2 and 3 is not important, as both have the same positive supply.


• Connect the brown/white cable to fuse 3.

• Connect the red cable to fuse 4.

• Fit fuse 1-4.

14. Fit the electrical centre:


• Secure the wiring harness with cable ties (D).

• Protect the wiring harness with heat resistant fabric tape (C).

• Fit the lower section of the electrical centre (B).

• Fit the electrical centre's cover (A).

15. Fit the extension wiring to the starter motor:

• Raise the car.

• Fit the extension wiring to the starter motor and secure.

• Insulate the positive connection to the starter motor using heat resistant fabric tape. Tape around the positive connection, route the positive connection around the engine wiring and tape together.

• Secure the extension wiring with cable ties.


• Lower the car.

16. Fit the extension wiring to the generator and secure:

• Fit the extension wiring to the generator.

• Secure the extension wiring with cable ties.


17. Fit the battery cover, lower section in accordance with WIS - Electrical System - Charging systems - Adjustment/Replacement

18. Fit the upper engine cover (A).



Warranty/Time Information

In the case of customer complaint and if the car is within the warranty period , use the following information to fill out the claim:

Failed Object: 37113

Fault/Reason code: 66

Location code: 09 (US=9)

Warranty Type (US): 01

Repair/Action code: 01

Labour Operation (US): 3711301

Labour Operation (CA): N0131

Time: 0.9 hr