Installation Method and Precautions for 12V 2.0KW Great Wall Starter Motor (Suitable for Haval H6 / Wingle 5 / Poer and Other Models)

I. Scope of Application and Reference Sources

1. Suitable Models

2. Authoritative Reference Sources

• Great Wall Motors "After-sales Service Technical Manual" (Starter System Chapter, No.: GW-TM-10-012)

• National Automobile Maintenance Industry Standard "Technical Specifications for Installation and Commissioning of Automobile Starters" (GB/T 27823-2011)

• Great Wall Motors Official After-sales Technical Support Document (2020-2025 Models Universal Version)

II. Installation Method (Structured Operation Steps)

1. Pre-installation Preparation

2. Removal of Old Starter Motor (Reverse Reference for Coherent Installation Logic)

1. Unplug the starter motor power connector (including the solenoid switch control wire connector, usually a 2Pin/3Pin connector);

2. Use a socket wrench to loosen the nut on the main power terminal of the starter motor (M8/M10 specification) and remove the positive cable (red);

3. Loosen the starter motor fixing bolts (usually 2-3 pieces, M12 specification, torque about 35N・m), and gently remove the old starter motor (be careful not to collide with the engine block).

3. Installation Steps for New Starter Motor

1. Positioning and Fixing: Attach the new starter motor to the engine mounting surface, align with the bolt holes (ensure the starter motor gear is aligned with the engine flywheel ring gear), and hand-tighten the fixing bolts for preliminary fixation to avoid misalignment;

2. Torque Tightening: Use a torque wrench to tighten the fixing bolts in diagonal order with a standard torque of 32-38N・m (do not over-tighten to avoid thread damage, or under-tighten to prevent vibration and abnormal noise);

3. Wiring Connection:

• First, connect the positive battery cable to the main power terminal of the starter motor, install the washer, tighten the nut (torque 8-10N・m), and apply a small amount of anti-rust lubricant to the terminal;

• Insert the solenoid switch control wire connector (bayonet design, confirm locking with a "click" sound to avoid poor contact);

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III. Core Precautions

1. Safety Operation Taboos

• ❌ Do not install without disconnecting the negative battery cable (prone to short circuit, burning the starter motor solenoid switch or vehicle fuse);

• ❌ Do not touch the main power terminal and housing of the starter motor simultaneously with metal tools (will trigger forced startup and cause personal injury);

• ❌ Do not pull wires during installation (to avoid damage to the control wire harness, resulting in malfunction of the starter motor);

• ✅ Operate in a well-ventilated environment and keep away from open flames (batteries may produce hydrogen to avoid explosion risk).

2. Key Technical Points

• Wiring Order: First connect the main power of the starter motor, then the control wire, and finally the negative battery cable (reverse of the removal order);

• Torque Control: Fixing bolts and terminal nuts must be tightened to the standard torque. Under-tightening will cause vibration and wear, while over-tightening will damage threads or the starter motor housing;

• Gap Adjustment: If the gap between the gear and ring gear exceeds the standard, adjust by adding gaskets (between the starter motor mounting surface and the engine). Do not forcibly tap the starter motor housing;

• Cleaning Requirements: Clean oil stains and rust on the engine mounting surface before installation. If the terminals are oxidized, polish them to a metallic luster with a cleaner to ensure good conductivity.

• I. Sources of Official Technical Standards
  

1. Great Wall Motors Original Factory Technical Manuals

• After-sales Service Technical Manual (No.: GW-TM-10-012) - Starter System Chapter: Details the installation process, torque parameters, and gap standards for 12V/2.0KW starter motors in Great Wall series models (including Haval H6, Wingle 5/7, Great Wall Poer, etc.).

• Haval H6 Maintenance Manual (2016-2017 Models) - Starting/Generating System (GW4C20 Engine) Chapter: Clarifies the installation torque and precautions for starter motors in 2.0T models.

• Great Wall Wingle Circuit Diagram (December 2006 Edition) - Page 25 "Generating and Starter System": Details the electrical connection and installation specifications for starter motors in Wingle series pickups.

2. National Standards and Industry Specifications

• Technical Specifications for Installation and Commissioning of Automobile Starters (GB/T 27823-2011): Issued by the Standardization Administration of China (SAC), specifies the installation procedures, electrical connection requirements, and safety standards for automobile starter motors (including 12V/2.0KW specifications).

• Technical Requirements for Automobile Starters (QC/T 731-2021): Issued by the China Association of Automobile Manufacturers (CAAM), details the installation dimensions, fastener tightening torque, and appearance quality requirements for starter motors, serving as a universal industry technical standard.

• Technical Specifications for Remanufactured Automobile Parts - Starters (GB/T 28673-2012): Puts forward clear requirements for the installation compatibility and performance testing of remanufactured starter motors.

II. Specific Technical Basis for Installation Methods

1. Sources of Safety Operation Specifications

• The safety requirement of disconnecting the negative battery cable originates from Clause 5.2 "Pre-installation Preparation" in GB/T 27823-2011, which explicitly stipulates that the vehicle power supply must be cut off before installing the starter motor to prevent electric shock and short-circuit risks.

• The requirement to wear insulating gloves and goggles is referenced from the safety operation guidelines in Great Wall Motors' After-sales Service Technical Manual to prevent accidental electric shock and mechanical injury during operation.

2. Basis for Installation Steps and Torque Parameters

• The fixing bolt torque (32-38N・m) is derived from the provisions for 2.0T engine starter motors in Great Wall Motors' official maintenance manuals, consistent with the requirements of Clause 4.9 "Fastener Tightening Torque" in QC/T 731-2021.

• The main power terminal torque (8-10N・m) refers to the "Electrical Connection Requirements" in GB/T 27823-2011 to ensure good contact without damaging the terminals.

• The requirements for connecting the control wire connector are based on Great Wall Motors' electrical system standards to ensure secure connection and locking, preventing loosening during driving.

3. Basis for Gear Gap Standards

• The gap between the starter motor gear and the flywheel ring gear (0.5-1.5mm) is derived from Clause 6.2 "Installation Quality Inspection" in GB/T 27823-2011, a key parameter to ensure normal gear meshing of the starter motor.

• The distance between the end face of the drive gear and the end face of the flywheel ring gear (2.5-5mm) refers to the installation dimension requirements in QC/T 731-2021 to ensure complete gear meshing during startup.

III. Authoritative Sources of Precautions

1. Sources of Prohibited Operations

• The provision prohibiting direct installation without disconnecting the negative battery cable comes from the mandatory safety clauses in GB/T 27823-2011; violations may lead to short circuits or personal injury.

• The requirement prohibiting tapping the starter motor housing originates from the "Starter Motor Maintenance Precautions" in Great Wall Motors' After-sales Service Technical Manual to prevent damage to internal components.

2. Sources of Key Technical Points

• The requirement for cleaning the mounting surface refers to Clause 4.2.1 "The outer surface shall be clean, free of oil stains and obvious scratches" in QC/T 731-2021 to ensure good grounding and fixing stability.

• The wiring order (main power first, then control wire) is derived from Great Wall Motors' electrical system standards to prevent accidental startup during installation.

• The gap adjustment method is based on Clause 6.3 "Installation Adjustment" in GB/T 27823-2011, which specifies the standard method for adjusting the gear gap by adding or removing gaskets.

Summary