JAGPURR
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4200 Starter motor overhaul.
If you start to hear a click-click sound from your starter without it turning the engine over, it's telling you that the solenoid contacts are on the way out. Or if like me the horrible noise of the starter cog not returning properly again means it's time for an overhaul. A new motor is about £350+ and one to two days labour to fit. If you fancy a weekend getting your hands dirty the motor can be overhauled for about £15 as follows.
Follow this link, Your car is not listed as such but contact Carl and tell him that you require a kit for:-
Denso starter 180169. 228000-9970 to fit Maserati 4200 V8
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=290434967359
Or contact Carl direct at carldawes@sky.com and mention the above details and me if you like, he will be pleased to help. For the sake of £15 it may be worth having a kit on the shelf, as you can bet your life it will go on a long bank holiday, or during a postal strike
Here we go then.
Remove the front exhaust/cat pipes. see ( 4200 front pipes/cat removal )
Remove the right hand exhaust manifold see ( 4200 exhaust manifold removal )
Disconnect or switch off the battery!
Lower the engine cowl enough to gain access to the starter.
Remove the three 13mm bolts holding the motor to the bell housing
Check you have disconnected the battery and then disconnect the mail battery lead from the starter motor and the solenoid lead just below it. Remove the two 5mm Allen bolts holding the steady bracket to the engine and the 5mm Allen bolt and nut holding the cable clamp to the bracket. You can now remove the starter motor.
Remove the steady bracket.
Remove the three small bolts holding the contact cover, retain the gasket.
Lift out the moving contact and retain the spring.
You can now see the fixed contacts. These are the parts that wear away causing the clicking as they fail to make a good contact. These are what we will replace.
The moving contact also wears and will be replaced.
This is the repair kit
The kit comes with full instructions but briefly, remove the nuts securing the fixed contacts and make note of the order of the seals and washers.
Reassemble with the new contacts and only tighten when the contacts are flat in the housing .I held them in place by pressing a socket against them while finally tightening the nuts.
Replace the new moving contact not forgetting the spring. And refit the cover.
If you want to check the brushes remove the two long bolts and then the two cross head screws and gently ease off the cover.
The brushes should be good for 200 thousand miles and after 50 mine showed no signs of wear. Just blow out any dust and replace the cover.
Removing the two long outside bolts also allows you to expose the gears, don't worry if bits fall out, just retrieve them and clean, reassemble as this picture with some new high temp grease. Check the operation of the drive gear, mine was all choked with dry grease so wash clean and apply some new grease sparingly.
When fully assembled you should try before refitting it the car as it's a long task to put back together and find you forgot a bit. Fit a temporary lead to the small connector on the solenoid. You could fix the motor in a vice and fit proper flying leads but this method is a lot easier. Using a pair of jump leads, negative to the starter body and positive to the large bolt terminal. Whilst steadying with your foot touch the temporary lead to the positive terminal and the motor should throw out the starting cog and spin freely. Only operate for a few seconds at a time as the motor will quickly overheat.
Everything fine? Then refit in the reverse order as above and give yourself a good pat on the back.
If you start to hear a click-click sound from your starter without it turning the engine over, it's telling you that the solenoid contacts are on the way out. Or if like me the horrible noise of the starter cog not returning properly again means it's time for an overhaul. A new motor is about £350+ and one to two days labour to fit. If you fancy a weekend getting your hands dirty the motor can be overhauled for about £15 as follows.
Follow this link, Your car is not listed as such but contact Carl and tell him that you require a kit for:-
Denso starter 180169. 228000-9970 to fit Maserati 4200 V8
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=290434967359
Or contact Carl direct at carldawes@sky.com and mention the above details and me if you like, he will be pleased to help. For the sake of £15 it may be worth having a kit on the shelf, as you can bet your life it will go on a long bank holiday, or during a postal strike
Here we go then.
Remove the front exhaust/cat pipes. see ( 4200 front pipes/cat removal )
Remove the right hand exhaust manifold see ( 4200 exhaust manifold removal )
Disconnect or switch off the battery!
Lower the engine cowl enough to gain access to the starter.
Remove the three 13mm bolts holding the motor to the bell housing
Check you have disconnected the battery and then disconnect the mail battery lead from the starter motor and the solenoid lead just below it. Remove the two 5mm Allen bolts holding the steady bracket to the engine and the 5mm Allen bolt and nut holding the cable clamp to the bracket. You can now remove the starter motor.
Remove the steady bracket.
Remove the three small bolts holding the contact cover, retain the gasket.
Lift out the moving contact and retain the spring.
You can now see the fixed contacts. These are the parts that wear away causing the clicking as they fail to make a good contact. These are what we will replace.
The moving contact also wears and will be replaced.
This is the repair kit
The kit comes with full instructions but briefly, remove the nuts securing the fixed contacts and make note of the order of the seals and washers.
Reassemble with the new contacts and only tighten when the contacts are flat in the housing .I held them in place by pressing a socket against them while finally tightening the nuts.
Replace the new moving contact not forgetting the spring. And refit the cover.
If you want to check the brushes remove the two long bolts and then the two cross head screws and gently ease off the cover.
The brushes should be good for 200 thousand miles and after 50 mine showed no signs of wear. Just blow out any dust and replace the cover.
Removing the two long outside bolts also allows you to expose the gears, don't worry if bits fall out, just retrieve them and clean, reassemble as this picture with some new high temp grease. Check the operation of the drive gear, mine was all choked with dry grease so wash clean and apply some new grease sparingly.
When fully assembled you should try before refitting it the car as it's a long task to put back together and find you forgot a bit. Fit a temporary lead to the small connector on the solenoid. You could fix the motor in a vice and fit proper flying leads but this method is a lot easier. Using a pair of jump leads, negative to the starter body and positive to the large bolt terminal. Whilst steadying with your foot touch the temporary lead to the positive terminal and the motor should throw out the starting cog and spin freely. Only operate for a few seconds at a time as the motor will quickly overheat.
Everything fine? Then refit in the reverse order as above and give yourself a good pat on the back.
