2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
DESCRIPTION Bosch starter is a brush-type, series-wound electric motor with an overrunning clutch. Field frame carries pole shoes and field coils, and is enclosed by commutator end frame and drive bushing. Armature shaft drive end drives a reduction gear.
TROUBLE SHOOTING NOTE:
See TROUBLE SHOOTING article in GENERAL INFORMATION.
REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Obtain radio code card from customer. Note stored stations and restore them after connecting battery. Stored settings of onboard computer and clock will also be lost. All available cental keys must be recoded for cars with first generation infrared transmitter locking systems. EXHAUST MANIFOLD WARNING: Danger of scalding. Only perform procedure after exhaust system has cooled down. NOTE:
Numbers in text refer to numbers in figures.
Removal & Installation
1. 2. 3. 4.
Remove center pipe to manifold flange bolts (1). See Fig. 1 . Disconnect both oxygen sensor connectors. See Fig. 2 . Remove retaining screws (1) for heat shield. See Fig. 3 . Remove retaining screws (1) for heat shield. See Fig. 4 . Remove heat shield (2). Note routing of wiring harness. 5. Remove 8 retaining screws (1) at exhaust manifold. See Fig. 5 . Remove exhaust manifold. 6. To install, reverse removal procedure. Make sure that mating surfaces of cylinder head and manifold are clean. Fit new gaskets. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Coat
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
threads of center pipe to manifold flange bolts with copper paste.
Fig. 1: Locating Center Pipe To Manifold Flange Bolts Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 2: Disconnecting Oxygen Sensor Connectors Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 3: Locating Retaining Screws For Heat Shield Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 4: Removing Heat Shield For Exhaust Manifold Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 5: Removing Exhaust Mainifold Courtesy of BMW OF NORTH AMERICA, INC. SOLENOID SWITCH CAUTION: Do NOT turn cable lug while tightening down. There is a risk of a short circuit to starter motor housing. NOTE:
Numbers in text apply to numbers in figures.
Removal & Installation
1. 2. 3. 4.
Turn off ignition. Remove starter. See STARTER . Remove nut (1). See Fig. 6 . Remove cable lug (2). Remove screws (1). See Fig. 7 . Remove solenoid switch (1) and spring (2). See Fig. 8 . Unhook pin (3).
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
5. To install, reverse removal procedure. Check pin (3) for wear and apply grease. Tighten nut for cable lug to specification. See TORQUE SPECIFICATIONS . Do NOT turn cable lug while tightening down.
Fig. 6: Removing Cable Lug Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 7: Removing Solenoid Switch Screws Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 8: Removing Solenoid Switch Courtesy of BMW OF NORTH AMERICA, INC. STARTER NOTE:
Numbers in text apply to numbers in figures. For clarity, some figures are shown on a removed engine.
Removal & Installation
1. 2. 3. 4. 5.
Switch off ignition. Disconnect battery. Remove exhaust manifold. See EXHAUST MANIFOLD . Remove bolt (1). See Fig. 9 . Release retaining clip (2). Remove heat shield. Disconnect battery positive lead (1). See Fig. 10 . Remove nut (2). Remove starter motor. To install, reverse removal procedure. Be careful of cable routing. Do NOT lay cable over solenoid switch. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 9: Removing Heat Shield Courtesy of BMW OF NORTH AMERICA, INC.
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
Fig. 10: Removing Starter Motor Courtesy of BMW OF NORTH AMERICA, INC.
TORQUE SPECIFICATIONS Torque Specifications Application Exhaust System-To-Exhaust Manifold Manifold Screws Starter Motor-To-Gearbox (W10)
Ft. Lbs. (N.m) 44 (60) 18 (24) 63 (85) INCH Lbs. (N.m) 124 (14)
Alternator Connection On Starter Electrical Leads-To-Starter 5 mm 6 mm
44 (5) 62 (7)
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2006 MINI Cooper S 2005 STARTING & CHARGING SYSTEMS Starters - Cooper & Cooper S
8 mm Engine Harness-To-Starter Solenoid Heat Shield-To-Cylinder Head Starter Motor-To-Heat Shield
115 (13) 71 (8) 115 (13) 80 (9)
WIRING DIAGRAMS For wiring diagrams, see WIRING DIAGRAMS in GENERATORS & REGULATORS article.
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