I just did the starter motor on my son's VS 3.8L auto ... thanks for the original post giving the info for how to remove the starter motor .. some extra info for the other first timers
, from what I observed..
1. I thought I'd try to see if I could get the starter motor out without undoing the exhaust manifold .... didn't work.. there just wasn't enough room ... it needs another cm or so of clearance to get the starter motor out. After much use of newly invented adjectives, I decided to undo the exhaust manifold and it came out easily & the new one slipped back in easily. Allow about an hour to get the starter motor out ... it took me longer than this because of the earlier comments about people having theirs come straight out without needing to undo anything else ... I was the optimist
... you may be lucky but be prepared to loosen the exhaust system.
The option of undoing the steering rack was also mentioned. I chose to not do this .. I looked at it and thought about giving a go.. The 2 nuts I thought that would need to be loosened seemed to be 18 or 19mm and seemed to be on very tight. I wasn't sure I could get them undone and if I could, if I get do them up tight enough later. I was just working at home with the car up on stands, so there wasn't a huge amount of room underneath to get a grip on things + I haven't had much experience with steering gear so I thought it best to stick with what I knew ( have made some costly mistakes in the past using this approach
, but I've learned a lot ...
!!! )
2. The original instructions didn't mention it explicitly but there is a support bracket directly under the starter motor (on the VS v6 ) covering up one of the bolts.
You'll need to remove this bracket. There's 3 x 13mm bolts. This is where you'll need the LONG socket extension handle (approx. 40cm in length ) + the 13mm socket to get to 2 of the 3 bolts. You get access to the bolts by coming in from the passenger side of the car.
Once you've taken off this bracket, it's very easy to get to the 2 x (15mm socket ) bolts holding the starter motor in. The bolts insert vertically from underneath.
3. Exhaust pipe clearance - the original instructions mentioned taking off the exhaust manifold. Another potential option would be to undo the 2 x exhaust pipe nuts holding the exhaust pipe onto the exhaust manifold. I didn't do this but its an option. As the original writer said, soak these in wd40 first ... if you break the bolts/ studs or strip them, you'll have a lot more work to fix them.
I undid the exhaust manifold studs. There are 6 of them .. KEEP TRACK of what's attached to them ... there is a bracket for holding the spark plug leads off the block and a bracket for the oil dipstick. These each mount onto different exhaust pipe studs.
I'd suggest you write down where these are attached too before you start unbolting things ... I didn't & had to guess where they went back.
The exhaust manifold nuts are 13mm. I found it easiest to get to them with a 13mm ring and then went out and bought a ratchet ring set ... SO much easier to work with them in the tight space ..
hope this is of use ...
john