Installation Method for Chery 12V 1.1KW Starter Motor

(General Standard Version)

I. Preparation (Mandatory)

1. Tools and Parts

• Socket / wrench set: 10mm, 13mm, 14mm, 19mm (core sizes)

• Torque wrench (accuracy ±5%), ratchet wrench, soft pry bar, insulated gloves

• Marker, multimeter, rust remover, high-temperature grease (NLGI Grade 2)

• New starter motor (12V 1.1KW; verify mounting feet, gear, B+ terminal, and control plug match the original unit)

• New mounting bolts (replace if old bolts are rusted or thread-stripped), flat washers + spring washers

• Vehicle lift + safety stands, wheel chocks, electrical tape, safety goggles

2. Safety and Vehicle Preparation

• Park the vehicle on level ground, turn off the engine, apply the parking brake, shift to neutral / P position, and install wheel chocks.

• Disconnect the 12V battery negative terminal and wait ≥3 minutes to discharge residual voltage (prevents short circuits and damage to the ECU / starter solenoid).

• Lift the vehicle and secure with safety stands; remove the engine undertray and right-side trim panel.

• Mark and photograph the routing of the starter wiring harness to record the positions of the B+ main cable, control plug, and ground cable.

• Clean the engine / transmission mounting surface to remove oil and rust.

II. Removal of Old Starter Motor (Reverse Procedure)

1. Disconnect Electrical Connections (DO NOT work with power on)

• Unplug the starter control plug (press the locking tab to ensure full separation).

• Use a 19mm wrench to remove the B+ main power cable nut, take off the cable, and immediately wrap the terminal with electrical tape to prevent short circuits.

• Disconnect the engine ground cable and mark it clearly.

2. Remove Mounting Bolts

• Chery starters are typically secured with 2 M12/M14 mounting bolts (located at the engine-transmission interface; use a 13/14mm socket).

• Loosen the bolts gradually in diagonal order; do not fully loosen at once.

• Support the starter, rock it gently to separate it from the flywheel ring gear, and remove the old unit (tap lightly if space is limited; do not pull forcibly).

• Inspect the flywheel ring gear for wear or broken teeth; repair if necessary.

III. Installation of New Starter Motor (Key Steps)

1. Positioning and Mounting (Critical Torque)

• Apply a thin layer of high-temperature grease to the starter drive gear shaft to reduce meshing friction.

• Align the new starter with the mounting holes and thread the mounting bolts in by hand (ensure smooth threading).

• Tighten the bolts gradually in diagonal order, strictly following OEM torque:

• Mounting bolts: 25–35 N·m (Chery standard for 1.1KW starters).

• Rock the starter gently to confirm no looseness or abnormal noise, and ensure smooth meshing between the drive gear and flywheel ring gear.

2. Electrical Connections (Prevent Short Circuits / Poor Connections)

• Connect the control plug first; ensure the lock clicks into place.

• Install the B+ main power cable: clean the terminal, install a flat washer + spring washer, and tighten the nut with a 19mm wrench. Torque: 12–15 N·m.

• Install the ground cable, reinstall per markings, and ensure a secure connection.

• Inspect all wiring harnesses: keep away from high-temperature/moving components (exhaust pipe, turbocharger, half-shaft, etc.) with no interference or pulling.

3. Reassembly and Final Steps

• Reinstall the engine undertray and right-side trim panel.

• Reconnect the 12V battery negative terminal.

IV. Inspection and Commissioning (Mandatory)

1. Static Inspection

• Visually check all bolts and wiring harnesses to confirm proper installation and no looseness.

• Check the starter housing for damage and the wiring harness for cracks.

2. Startup Test

• Turn on the ignition; the dashboard should show no abnormal fault lights.

• Start the engine; the starter should run smoothly with no abnormal noise, and the gear should engage / disengage smoothly.

• At idle / during acceleration, the starter should show no slipping or unusual noise.

3. Electrical Inspection

• Measure cranking voltage with a multimeter: ≥9.0V (starting system standard).

• Check the B+ terminal and wiring harness for overheating, burning, or unusual odors.

4. Functional Verification

• Perform 3 consecutive start tests with an interval of ≥15 seconds between each; the starter should operate normally.

• The engine should start quickly with no gear grinding or slow cranking.

Installation Precautions for Chery 12V 1.1KW Starter Motor

Complete Detailed Version

I. Safety & Power Disconnection Specifications (Top Priority)

Must Disconnect the 12V Battery Negative Terminal First

• Turn off the engine → apply parking brake → shift to neutral/P → disconnect the battery negative terminal, and wait ≥3 minutes before starting work.

• The starter B+ terminal is a constant-live high-current terminal. Operating without disconnecting power can easily cause short circuits, wire burning, fuse failure, ECU breakdown, and starter solenoid burnout.

Never Plug/Unplug Any Starter Connector/Terminal With Power On

• All work must be performed only after complete power disconnection. Otherwise, it will directly burn the starter, damage the control module, and cause wiring fire.

Insulate the B+ Main Cable Immediately After Removal

• Wrap the cable end tightly with electrical tape right after removal.

• Strictly prohibit grounding, contact with any metal components, or friction with other wiring harnesses.

Work Safety

• Use safety stands when lifting the vehicle; never rely solely on a jack.

• Keep away from high-temperature/moving components (exhaust pipe, turbocharger, half-shaft, pulleys, fan, steering and hydraulic lines, etc.) to prevent burns, pinches, and crush injuries.

II. Precautions for Removing the Old Starter Motor

Take Photos to Record Wiring Routing & Positions First

• The engine compartment is compact with dense wiring. Incorrect installation may cause wiring chafing, short circuits, or starting failure.

Follow the Correct Disassembly Sequence

• Disconnect wires first → then remove bolts. Never remove bolts before disconnecting wires to avoid terminal breakage from wire pulling.

Prohibit Violent Bolt Removal

• If bolts are rusted, spray rust remover and wait 5–10 minutes before loosening.

• Strictly forbid forced twisting, aggressive impact wrench use, or excessive breaker bar force to avoid thread stripping, bolt breakage, transmission housing damage, or mounting bracket cracking.

Do Not Pry the Gear, Solenoid, or Wiring Areas

• Support or pry only the starter main housing or mounting feet.

• Do not pry on the drive gear, solenoid, terminals, or plug areas to avoid internal damage or total failure.

Support the Starter Securely When Removing

• Avoid dropping and damaging the engine mount, oil pan, water pipes, vacuum hoses, wiring harnesses, or transmission housing to prevent major secondary damage.

Inspect the Flywheel Ring Gear After Removal

• Check for wear, broken teeth, gear scuffing, or deformation. Repair any issues first; otherwise, the new starter will be damaged.

III. Pre‑Installation Inspection of the New Starter (Mandatory)

Verify Full Specification Match

• 12V 1.1KW. Mounting foot position, gear tooth count/size, B+ terminal position, plug shape, and mounting hole spacing must be completely identical to the original.

Appearance Inspection

• No bumps, cracks, oil leaks, water intrusion, rust, or deformation.

• Drive gear must be free of chipped teeth, wear, or jamming.

Drive Gear & Overrunning Clutch Inspection

• Rotate the gear by hand: smooth rotation in one direction and lock in the reverse direction is normal.

• Free rotation in both directions / no rotation in either direction = defective starter; do not install.

Terminal Inspection

• B+ terminal and control plug must be free of oxidation, deformation, looseness, or burning marks.

Do NOT Install a Damaged Starter

• If any abnormality is found in appearance, gear, terminals, or clutch, replace it immediately. Do not install a defective unit.

IV. Detailed Installation Precautions

1. Mounting Surface & Fixing Bolts (Critical)

• Thoroughly clean the engine/transmission mounting surface to remove oil, debris, and deformation, ensuring a flat, evenly loaded fit.

• Thread bolts in by hand for 2–3 turns first to confirm smooth threading; do not force-tighten.

• Tighten bolts gradually in diagonal order; do not fully tighten in one pass.

• Strictly follow Chery OEM torque specifications:

• Starter mounting bolts: 25–35 N·m

• Consequences:

• Too loose: vibration, abnormal noise, looseness, gear grinding, housing cracking

• Too tight: thread stripping, transmission housing cracking, bolt breakage, starter housing rupture

• References：
  

• Installation Precautions for Chery 12V 1.1KW Starter Motor

• Authoritative Sources (Formal Citable Version)

• Suitable for repair work orders, export technical documents, and product manuals with a professional and rigorous format.

• I. Authoritative Basis

• 1. Chery Automobile OEM Service Manual

• Applicable Brands / Models

• Chery: All passenger vehicles and commercial vehicles

• All Chery platform models equipped with 12V 1.1KW gear‑reduction starter motor

• Applicable Systems

• 12V starting system

• 1.1KW gear‑reduction starter (standard for Chery mainstream small‑displacement engines)

• Chapters

• Engine Electrical System → Starter Motor Removal and Installation

• Service Specifications → Torque Standards and Assembly Procedures

• Basis Content

• Starter mounting bolt torque: 25–35 N·m

• Starter B+ power terminal torque: 12–15 N·m

• Flywheel ring gear and starter drive gear meshing clearance standard

• Starter mounting surface cleaning and assembly process requirements

• 12V electrical system power disconnection safety operation specifications

• Wiring harness routing, fixing, anti‑abrasion, and anti‑high temperature requirements