Tech Talk
We don’t profess to know everything there is to know about servicing every vehicle out there, but we’re smart enough to know there are too many to be that good. But we can say this, there are very few starters, alternators or wiper motors on engines (from cars to ATVs) that we have not removed and replaced. Our team of experts has worked hard to make Premier Gear an easy-to-do job. Premier Gear is not just for those of you that do this occasionally, but is for the working pros that need to make up time on other service projects. Our goal is to help you remove, replace, and get you back running again, without any problems (and of course, with no core to return).
Before you get started, take a few tips from our pros–it’ll help make the job go smoothly. Our Tech Tips will help you with a diagnosis – locating the right replacement part, removal of the old unit, and replacement of your new Premier Gear unit. And save the box… it will look good on your garage shelf.
Tech Tips
Starter Removal & Replacement
At Premier Gear, we know your time is valuable. We want to help to ensure that you have the best starter installation experience possible. Don’t worry, we will guide you through every step of the way, and in no time, you’ll be cranking it up and rippin’ down the road.
The tech tips below should serve as a general guide for starter removal and installation.
BEFORE REPLACING THE STARTER
A few things to know before you get started:
1. Verify the starter is nonfunctional. The starter can be tested using a carbon pile load tester, a voltmeter and clamp-on style ammeter.
2. Check and follow all safety precautions outlined in the vehicle manufacturer’s service manual.
3. Verify the batteries are fully charged and battery terminals are clean and firmly in place. Check battery cable for any corrosion or tears in the insulation.
4. Verify all fuses are good.
5. Check all wiring connections leading to the starter for discoloration, cracks, or evidence or overheating. If any of these symptoms are present, connections must be replaced. Failure to do so may result in starter or vehicle damage.
REMOVAL INSTRUCTIONS
1. Disconnect all wire connections and plugs from the starter, noting their location and identifying each connector with a piece of tape. This will make installation of the replacement starter easier.
2. Loosen the starter mounting bolts. Note the location of any shims, heat shields, and support brackets. This will also make installation of the replacement starter easier.
3. Remove mounting bolts, tilt or rotate starter to clear flywheel and transmission housing and remove starter from vehicle, noting position of any shims. Shims may be stuck to either the engine mounting or the mounting pads of the starter.
4. Inspect starter drive teeth for damaged pinions. If drive is damaged, it is extremely important that you inspect the flywheel or ring gear for broken or worn teeth (see figure below). A broken or worn ring gear must be replaced or it will damage the new starter.
Keep in mind, with Premier Gear, there is no core to return.
INSTALLATION INSTRUCTIONS
1. Check and compare the original starter to the replacement starter. All mounting holes, wire and plug connectors, and hardware should be compatible. Some vehicle manufacturers may use more than one starter manufacturer. Slight differences in the starter’s appearance will not affect the performance of the starter.
2. Install the replacement starter reusing all mounting hardware from the original starter. Refer to vehicle service manual and torque nuts and bolts to the manufacturer’s required specifications.
3. Reconnect all electrical connections of the replacement starter to the correct terminals. It is important that all connectors must be clean and fit properly.
4. Reconnect battery cable, connecting positive connections first.
BEFORE REPLACING THE STARTER
A few things to know before you get started:
1. Verify the starter is nonfunctional. The starter can be tested using a carbon pile load tester, a voltmeter and clamp-on style ammeter.
2. Check and follow all safety precautions outlined in the vehicle manufacturer’s service manual.
3. Verify the batteries are fully charged and battery terminals are clean and firmly in place. Check battery cable for any corrosion or tears in the insulation.
4. Verify all fuses are good.
5. Check all wiring connections leading to the starter for discoloration, cracks, or evidence or overheating. If any of these symptoms are present, connections must be replaced. Failure to do so may result in starter or vehicle damage.
REMOVAL INSTRUCTIONS
1. Disconnect all wire connections and plugs from the starter, noting their location and identifying each connector with a piece of tape. This will make installation of the replacement starter easier.
2. Loosen the starter mounting bolts. Note the location of any shims, heat shields, and support brackets. This will also make installation of the replacement starter easier.
3. Remove mounting bolts, tilt or rotate starter to clear flywheel and transmission housing and remove starter from vehicle, noting position of any shims. Shims may be stuck to either the engine mounting or the mounting pads of the starter.
4. Inspect starter drive teeth for damaged pinions. If drive is damaged, it is extremely important that you inspect the flywheel or ring gear for broken or worn teeth (see figure below). A broken or worn ring gear must be replaced or it will damage the new starter.
Keep in mind, with Premier Gear, there is no core to return.
INSTALLATION INSTRUCTIONS
1. Check and compare the original starter to the replacement starter. All mounting holes, wire and plug connectors, and hardware should be compatible. Some vehicle manufacturers may use more than one starter manufacturer. Slight differences in the starter’s appearance will not affect the performance of the starter.
2. Install the replacement starter reusing all mounting hardware from the original starter. Refer to vehicle service manual and torque nuts and bolts to the manufacturer’s required specifications.
3. Reconnect all electrical connections of the replacement starter to the correct terminals. It is important that all connectors must be clean and fit properly.
4. Reconnect battery cable, connecting positive connections first.
Alternator Removal & Replacement
WARNING: ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE -INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY ALTERNATORS. FAILURE TO USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE. Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical capabilities should be handled by a professional installation specialist.
WARNING: To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator. The alternator output terminal is always live (“hot’). If the battery is not disconnected, a tool accidentally touching this terminal and ground can quickly get hot enough to burn skin or damage to the tools and surrounding parts.
PULLEY INSTRUCTIONS: Use pulley from old alternator if this alternator does not have a pulley or pulley supplied is different from the one on alternator being replaced. NOTICE! When changing the pulley, keep the alternator in the ¬horizontal position and do not apply any pressure to end of the shaft. Internal damage will occur if the shaft is pushed back and turned. If there were spacers. when the fan and pulley were removed, make sure all spacers are replaced when installing the fan and pulley on this alternator. Hold the shaft by placing a hex wrench in the hexagonal hole in the shaft while removing or installing the pulley. Tighten the pulley nut to 95-108 Nm (70-80 Ib ft).
BELT TENSIONING INSTRUCTIONS: Improper belt tension can cause premature .alternator failure. If the belt must be tightened manually, place a wood block between the alternator and pry bar, as illustrated. Pry as close to the center of the unit as possible. Use a torque wrench to tighten mounting bolts to specified torque. Follow vehicle or engine manufacturer’s specifications carefully for belt tension and mounting bolts torque. DO NOT OVER TIGHTEN BELT!
TERMINAL DESCRIPTIONS:
“POS” Terminal – Output terminal connects to the Positive (+) Battery terminal.
“R” Terminal – Relay terminal carries half systems voltage and may be used for certain types of control relays, charge indicators, tachometers or similar devices. The current draw should not exceed four (4) amperes. Notice! Do not install the remote sense lead to this terminal.
“I” Terminal – Indicator lamp/Ignition terminal carries full system voltage. Current draw should not exceed one (1) ampere. It is recommended current is not drawn from this terminal.
Ground Screw – Ground lead ensures alternator is grounded and is strongly recommended for optimum performance.
“Remote Sense” Terminal – Monitors batteries system voltage at the Batteries or a common distribution point. The Sense terminal is the fourth terminal and is identified with a “remote sense” label on the back cover plate. Notice! Do not connect anything but the remote sense line to this terminal.
• If installing a remote sense alternator in a vehicle without a remote sense line, connect a lead from the Voltage Sense terminal to the Positive (+) Battery terminal or the common distribution point at the Starter Solenoid Battery (+) terminal.
• If installing a non-remote sense alternator in a vehicle that has a remote sense line, disconnect and secure the wire from the battery. Notice! Be careful not to ground the leads open end and if it has a fuse it should be deactivated.
• • Only connect the sense line to the remote sense terminal. The “R” Terminal is Not the Remote Sense Terminal!
INSTALLATION INSTRUCTIONS:
• Disconnect the negative (-) cable at the batteries.
• Identify and tag all leads when removing the old Alternator and install them on the same terminals of the new Alternator.
• Insure all leads are hooked back up or contained where they can not ground.
• Torque all fasteners to values labeled on the illustration.
• This Alternator may have more terminals than the alternator it is replacing had or used. It will function properly by only hooking up the leads that were used on the alternator being replaced.
Wiper Motor Removal & Replacement
At Premier Gear, we know your time is valuable. Replacing your windshield wiper motor is very important because this motor operates your wipers and allows you to clean the rain, snow and dirt off your windshield. It is also a relatively easy task. Quite easy for the pro DIYer.
BEFORE REPLACING THE WIPER MOTOR
Remove the wiper blades to gain access to the windshield wiper motor. Use a windshield wiper removal tool to release the tension on them so you can easily remove them. Check the wiper blades for wear and replace if needed.
REMOVE THE WIPER MOTOR
#1 Unplug and unbolt the wiper motor from the wiper gearbox assembly that connects the wiper blades to the motor. Once this is complete, you can remove the old motor for replacement. Save all fasteners.
#2 Install the new Premier Gear windshield wiper motor. Remount the new windshield wiper motor back onto the wiper gearbox assembly, using the same fasteners. Bolt it back onto the cowl housing and plug it back in, then reinstall the cowl plastic and the clips.
#3: Reconnect the wiper arms. Once complete, install the new Premier Gear wiper motor and putting the cowl back together, reinstall the wiper arms and wiper blades onto the wiper gearbox assembly.
#4 Tighten them down to the correct torque specs. Check to ensure the wiper blades are in the correct location so that when you activate them they will clean the windshield properly. If they don't, you can always readjust them.
WINDOW LIFT KIT PROCESS
Replacing a window lift motor (and armature) is a task that most serious DIYer’s can tackle, it is however a lengthy and somewhat challenging procedure. Rather than try to provide complete details on this procedure, we suggest using the power of the Internet, to provide you with information (websites and videos) that can help show you how to do it right.
On YouTube alone, there are many videos available (some specific to what could be your vehicle) that go through this replacement process one step at a time. You can also Google: Window Lift Motor Replacement and find many helpful instructions and tips for doing a professional job in your own garage.
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