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More resources below (page 1)
Background: Lancia Ypsilon 1.3 JTD (70HP) DFN [2004] km: 168673 Years of service: 18.5 Issue: starter motor showing signs of weakness. Meaning, motor stops turning after (much) less than 1 full crank rotation. No error messages on dashboard. Power off and reset of ignition sequence start got me running twice but it was obvious that this was a top priority issue and that the starter motor was EOL (end of life). Note that my battery was less than 6 months old. Original FIAT references: STARTER MOTOR 46823548 components: SOLENOID 77362732 LEVER 77362735 PINION 77362731 REDUCTION GEAR 77362737 ARMATURE 77362730 WINDING 77362733 BRUSH HOLDER 77362734 KIT STARTER MOTOR 77362736 The question now is: to repair the existing one or to buy a completely new one? Given the price of the completely new one, I would recommend to buy a new spare part. So, I bought the following from autodoc: VALEO NEW ORIGINAL PART 438168 Anlasser 12V 1,3kW, Zähnez.: 9 Meaning: 12 Volts, 1.3 kW, 9 teeth, rotation as shown in images. Since space is extremely limited in my configuration, the images at the end of the album give an idea of the length of my extension and the drinking straw. Extension: 16 cm Straw: 15 cm In other words, I had a total length of 16 cm to screw and unscrew the upper torx 45 bolt. Anything longer than that was conflicting with the DFN/selespeed clutch position sensor. So, after validating the total length of 16 cm with a 3/8 inch extension, I changed my rachet size from 3/8 inch to 1/4 inch. The 1/4 inch rachet configuration allowed me to have a total length of rachet + extension + torx bit holder + torx bit of 15 cm. This eliminated the conflict with the clutch position sensor (Image5311, Image5312, Image5314, Image5535, Image5536) Please kindly make sure you watch the 3 following videos showing the same procedure for 1.3 FPT engine on different configurations, compared to mine. 1/3: Starter motor Fiat Linea, Punto, Dobló. Alfa Romeo MiTo. How to replace! (Alfa Romeo? No Problem!) https://www.youtube.com/watch?v=MtZTzDtZkRk 2/3: Vauxhall Corsa E 1.3 CDTI Starter Motor Removal Replacement (IAMASPANNER) https://www.youtube.com/watch?v=PT3snpN_rpY 3/3: COME SI CAMBIA IL MOTORINO DI AVVIAMENTO FIAT (SHARKY 320) https://www.youtube.com/watch?v=R4oNOjqY6Gw Useful info (PDFs) : FIAT ePER46823548.pdf FIAT ePER46823548 components.pdf 5520B10 STARTER MOTOR - R+R - Lancia - Ypsilon - eLearn - 4CarData.pdf A20 STARTER' MOTOR - Lancia - Ypsilon - eLearn - 4CarData.pdf A1B BATTERY ( BATTERY NEGATIVE ) - Lancia - Ypsilon - eLearn - 4CarData.pdf A20A STARTER' MOTOR ( BATTERY POSITIVE ) - Lancia - Ypsilon - eLearn - 4CarData.pdf A20A STARTER' MOTOR ( RECHARGING ) - Lancia - Ypsilon - eLearn - 4CarData.pdf A20B STARTER' MOTOR ( ENGINE ) - Lancia - Ypsilon - eLearn - 4CarData.pdf 438168 VALEO NEW ORIGINAL PART D6G32 Anlasser 12V 1,3kW, Zähnez._ 9 ▷ AUTODOC Preis und Erfahrung.pdf 458191 VALEO REMANUFACTURED PREMIUM D6G32 Anlasser 12V 1,3kW, Zähnez._ 9 ▷ AUTODOC Preis und Erfahrung.pdf ERA EC.pdf Bonus: refit checklist!!! 01. With the starter motor out of the way, now is a good time to take a picture of the alternator reference, because we never know what's next. 02. since your battery has been out of the car for a while, now's a good time to charge your battery with your favourite battery charger 03. print a sticker for historic reference 05. compare old starter motor to new starter motor 07. dry electrical test run of new starter motor. Spins OK? Engages OK? Rotation direction OK? 08. clean contact surface between starter motor and engine block 09. WD-40 on nut of metallic turbo hose on engine block (only if necessary, Image5344, Image5349, Image5350) 20. clean torx 45 bolts 21. test fit torx 45 bolts into engine block + starter motor 22. prepare a drinking straw for next step (Image5508, Image5509, Image5510, Image5511, Image5512) 23. prepare upper torx 45 bolt to penetrate engine block 24. Take note of the rachet extensions sizes as mentioned above (end of album) 30. screw by hand the upper torx 45 bolt while feeding the starter motor underneath the car (in case you have an assistant available. If you're on your own, you'll need to fiddle a bit) 31. screw by hand the lower torx 45 bolt 32. tighten the upper torx 45 bolt to 23 - 28 Nm 33. tighten the lower torx 45 bolt to 23 - 28 Nm 34. tighten the starter motor electrical cable tie "sandwich" with a 13mm hex nut 35. place historic reference sticker on new starter motor, visible when car is on lift 36. re-tighten metallic turbo hose on engine block (only if necessary, Image5344, Image5349, Image5350) 37. re-clip turbo hose with heating tube (only if necessary) 38. take a pic of selespeed fluid level (only if necessary) 39. refit selespeed tank alloy shield with 4x 10mm hex nuts (only if necessary) 40. fix and tighten turbo hose with intercooler (only if necessary) 53. replug the 3-pin clutch position sensor (Image5311, Image5312, Image5314, Image5535, Image5536) 55. re-fit the plastic selespeed relay and fuse holder (Image5538) 56. fix and tighten battery tray 57. fix and tighten glow plug relay 58. fix and tighten battery with belt 59. fix and tighten battery terminals 65. FINAL visual check 66. prepare to execute next 4 steps with the glow plug temperature in mind 68. WITHOUT starting the engine, power-up car with key to MAR 69. Set you gear to neutral 70. Do you see any alerts? 72. If you don't see any alerts... GO engine START, GO-GO-GO baby!!! 80. take note of odometer status kms _ _ _ _ _ _ and date _ _ - _ _ - 2 0 _ _ 85. Go for a test drive (all 5 forward gears + reverse + neutral) Best of luck with your project!!! Questions? Comments? Concerns? LANCIA -at- danaus -dot- NET
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