Hello,

not really been active on the forum, but have been reading a lot quietly. I ressurected a flooded XJ81, which is giving me a real mechanical headache at the moment. The starter was since recovery not great and has ceased to function altogether. Upon ignition it just blows the fuse. So I went to the quest to remove the starter, impossible without the right tools or the possibility to lift the car.
I removed the downward exhaust pipe from the manifold which took me a good 3 hours, even though 3 of the 4 bolts came of easily. Once the starter was free I got confused. On all post that I read on various sites, the starter is bolted from the starter side and not from the back. Mine is a 94 model, so I thought there may be differences in the way mounted. I managed to remove the lower bolt of the starter, which came out well.
The top one was a challenge as it was sitting much higher and was almost impossible to remove. After removing this bolt, I realized that it looked different. The long one came out on the bottom the short one from the top.



I hammered on the starter but I moves maybe a millimeter at the botttom at best. So I took an endoscope and looked at the top mounting on the starter:



Looks to me like a snapped bolt, or am I missing something? Here a pic of the tranny tunnel:




The bottom left hole is where the long bolt was removed. The top ist almost impossible to fotograph, but I fear this is a transmission mounting bolt.

I am seriously frustrated with this starter removal. Has anyone got ideas on how to proceed?

Thanks

Rob

 

Your photos are not loading. Make sure they are in .jpg format.

Larry

 

Hi Larry,
I pasted the photos directley into the text box, on chrome they show up. Maybe a browser issue?

Br
Rob

 

I believe you have to add photos via the photo icon in the text box, dragging and dropping does not work.

Larry

 

Hi Larry,

noted with regards to the pictures. I used the endoscope to investigate further, and I seem to have missed the bolt. It is a totally different head to the lower one, I believe US 6/17'th or 12 tooth. I ordered via Amazon the tools, lets see if the starter will come out.

Br
Rob

 

I have removed and replaced several starters on six cylinder XJS, XJ40 and X300 cars over the years. THE problem is aluminum oxide cementing that bolt into the starter. Two cures: a carefully applied small propane torch to the started housing to break the aluminum oxide OR drill through and destroy the starter housing to remove the bolt. The best access for the job is to remove the intake manifold and windshield wiper motor assembly. Upon install of the new starter use anti-sieze compound on the two bolts. A PIA job for sure.

 

Hi,
i finally managed to get the starter out, but what a job!
With several extensions and the 6/17 adapter it was impossible, so I decided to cut out a piece of the tranny tunnel. My measurements were spot on, and the bolt was out in 2 min.
unfortunately the newly sourced starter does not fit. I now ordered a replacement for the Magneti Marelli which was about 325€.
Let’s see if she starts again once the new starter is inside.

 

I like the idea of cutting a hole in the floor!

 

Not in the floor but in the transmission tunnel! It’s a 2 inch by 2 inch which will be welded back again.
Other alternative would be to pull the engine out, which was not really an option.