Bus starter replaced

Brief post today about replacing the starter in the TDI-powered microbus.

Beginning by Not Starting

After getting the radiator replaced, I was unable to take a test drive because I couldn't get Hapy started. I assumed it was the annual ignition wiring issues, but I was wrong. The great unwiring I did two years ago (See Another Tow) actually worked two years later. The true issue was the starter finally failed. The starter that I was using was a gift from Justin. He had a customer who was complaining about noises coming from their starter, even though it worked fine. It kind of ran-on a couple of seconds after releasing the key post-start. While this is an indication of impending failure, it was working fine. Justin replaced it, and offered me the starter for the project microbus. It being free, I obviously accepted it, knowing that the day would come when the starter would become inconsistent and then just not work. Well... the becoming inconsistent didn't happen; it just failed.

Start Out
Removing a starter is not complicated, but I'll cover it anyway. Disconnect the battery cables from the battery first. This should be obvious, but so often we get excited about the job, and forget. Next, unplug the trigger wire that comes from the ignition and plugs into the solenoid with a small black square clip. Pinch-and-pull. Next, remove the bundle of wires which are ring-terminal'd onto the back of the starter. This should be a 10mm nut. With the electrical out of the way, grab the (IIRC) 19mm socket and remove the top bolt. This bolt is longer than the other, and you go after this one first on the bus because it is the one that is harder to get to (you're on your back facing up). Then, remove the lower, smaller bolt from the bottom, keeping a hand on the starter as it loosens. It is heavy, especially lying down underneath, so brace against it falling on your face.

Start In
I took the old starter over to Discount Import Parts (now only on the east-side - don't get me started) and got a rebuilt Bosch from them. Since I had the old starter in hand, I didn't have to pay a core nor drive all the way over there a second time. The install is literally the reverse of the removal: wrestle the starter up into position (solenoid above the starter) and rotate it left and right while pressing the smaller bolt into the lower hole. Once it catches, thread it in with your fingers until it is holding. Then, finger-in the top longer bolt. Once they are both finger tight, tighten with the sockets. Wire up the ring-terminal wires with the 13mm, then plug in the trigger wire.

Once the starter was in, Hapy fired right up. His test drive was pretty great. A charged-air pipe separated from one of the rubber connectors again, so I'll need to solve for keeping that together. Otherwise, I drove to the gas station and filled up with B20. Last tank of fuel: 39mpg. When compared to the 16-19 mpg I was getting with the gasoline engine, 39 is absolutely astounding. I rewarded Hapy with an oil change.

That's it for today. Thanks, as always, for following along-