The PowerLite doesn’t need the bush but there is no need to remove it. Looks like there is or has been an oil leak into the bellhousing, clean out what you can reach but it doesn’t really matter if you leave it and there is nothing that needs lubricating in there.
The fated day has arrived...wish me luck...i’m goin under! Well, after lunch that is. Since it can cause no harm i’ll clean up what I can (leave the bush in place) and that way in a year & 1 minute I can see if more oil has leaked. What would cause oil to get in there and how concerned should I be? Instructions state it can be orientated either way, so i’ll let the frame & wiring dictate that. So I just shove it in (battery disconnected), bolt it up () then connect the wires as they once were. Nothing in the manual about what those 2 black things are. Sent from my iPhone using Tapatalk
Well, it’s on! Bag of sand seemed to hold the infamous D Bolt in place. Instructions stated to not have any pressure on the Spade Terminal. Only just managed to manipulate the wires to reach and be orientated to fit snuggly. Consequence of this is that the wire from the Spade Terminal is touching the large (foremost) copper Ring Connector. Is this a problem? Melting...possible sparks under fuel tank? I’m now too scared to try it until i’m told to! ha ha Tightened things as best I could but i’ve no idea what is tight or loose i’m afraid. I’m strong. I don’t trust my own work. Hate not knowing what i’m doing with expensive and potentially dangerous things. Sent from my iPhone using Tapatalk
Ok. Cheers. I’ll give it a go. Had to pull at it a bit just to make it reach that little bit further than for the old motor. Sent from my iPhone using Tapatalk
That’s the best I can do. A 1mm clearance but things move on a vehicle don’t they Instructions state not to over tighten the Stud Connector. Reckon i’m on the limit of that to hold the heavy cable in place. Sent from my iPhone using Tapatalk
Or you could bend the spade (on the wire) in the middle say 20-30° so it points away from the lug terminal.
Thanks. Had another look and looped that spade one over the top, then under. Good amount of clearance now even with movement. However...tried starting it and just a loud whirring noise. Didn’t start Sent from my iPhone using Tapatalk
The engines going round but what a racket! My stock starter turns my high compression 2.4l twice that speed. Something isn't right. Did you try it off the bus? You can do that with self supporting. Did you tighten both the bolts? Is the throw correct? Too much might be bad. On your photo with old and new starters, the gear on the new one looks much longer. You may have the wrong one.
It’s a horrid noise hey! I didn’t try it because it’s fresh out the box. Contacted Powerlite directly to confirm which model...with images and info of what was being replace. Both bolts done up nice and firmly. I’m clueless. Sent from my iPhone using Tapatalk
You might have missed my edit, but the photo earlier showing old and new starters looks like you have the wrong one. The drive gear is sticking out so far it's probably a good job it didn't start!
Ah, gotcha. Yes, I missed the edit. It does look longer in the photo. I didn’t think anything of it having confirmed with Powerlite. I’ll email them again tomorrow. Though I actually purchased it from JK, so if it’s wrong then i’m not sure where I stand on a return. In the mean time I won’t try starting it again! Thank you. Sent from my iPhone using Tapatalk
Your not having much joy with this simple task Starter doesn’t look right compared next to each other. Sounds awful
I certainly feel cursed when it comes to this campervan. Knowing there were 2 options for motors I did the sensible thing of exploring 3 avenues avoid this very scenario - even 50/50 odds weren’t in my favour I’ll send Powerlite the video & photos tomorrow, but they were adamant I buy the 525...so if it turns out they were wrong (not even sure how to prove that when they had the serial number of the old one...unless that was ‘modified’), I’ll have to beg them to exchange it. I’ll double check what i’ve done too, but it was a straight swap really, with some Zedders fine tuning Sent from my iPhone using Tapatalk
When you take it off, look in the hole and see if that horrible noise was the gear drilling into the bell housing. Perhaps don't send them the video, they might refuse to take it back.
The black tubes are probably points for vent tubes so you can submerge the starter in water, if PVC tubes are pushed in and led to a dry place.. But looking at the pictures, your new starter has a gearbox in it, the solenoid and the motor are swapped. So the racket is probably that gearbox and normal. But the outer edge of the gear sticking out has to be be out of mesh with the flywheel at rest. If it isnt, as the engine fires, the motor will stall it immediately.. I would take out the starter and measure the distance from the lip on the fixing hole to the flywheel teeth and compare it with the distance from the outer edge of the gear to the part of the motor body that touches the lip on the fixing hole. When the solenoid fires, that gear is meant to jump out to engage with the starter ring, and then spring back out of the way when the starter is turned off. A true bodger would cut a spacer plate out of some 5mm aluminium sheet. Electrically would stick some sleeving over the spade terminal near the battery wire- off a piece of mains cable for instance..or self amalgmating tape A wise man would send it back and buy a cheap exchange starter and have done with it. At rest as it should be Stock - distance is d1 alternative - distance is d2 Basically d1 is small enough to miss the flywheel at rest, d2 is too large. OR ITS FAULTY AND THE ENGAGEMENT MECHANISM IS JAMMED !!! Try prodding it..
Ok. I’ll do just that. On installation it can be orientated either way, so I put it where it had the most clearance and existing cables could still reach. Gotcha on the spade insulation I chose the Powerlite because it was highly recommended as a replacement. My old one couldn’t have lasted very long and i’ve read so many horror stories about cheaper replacements I figured the wise thing to do was spend twice as much for half the potential hassle ha ha I have Powerlite the engine number, manufacture date and serial number of the one i’m replacing - so I don’t understand how it can’t be right unless i’ve botched installing it. ha ha it is a horrendous noise though!! If it makes that noise as ‘normal’ then i’ll be sending it back anyway Thanks Mike. Sent from my iPhone using Tapatalk
See my edits, there might be a problem with the new one. Sometimes though once its unstuck it may be perfect forever. That gear is meant to move with the solenoid..
