Starter 3708010A53DJ QDJ2840T CA6DM242E4, CA6DM242E5, suitable for FAW

Pre-installation Preparation

Component and Tool Preparation

• First, confirm that the model of the new 24V starter is compatible with the engine of the corresponding FAW vehicle. Check that the starter housing is free of damage and all components are complete.

• Prepare tools such as box-end wrenches, sockets, a torque wrench, and Phillips screwdrivers. Meanwhile, apply grease to the bearings and sliding parts of the starter to reduce friction during assembly.

Power-off and Cleaning

• Turn off the ignition switch, remove the key, and disconnect the negative battery cable to avoid short circuits that may damage electrical components during installation.

• Then clean the starter mounting surface at the junction of the engine and transmission. Wipe off oil, rust, and dust with a cloth to ensure the mounting surface is flat, preventing the starter from shaking during operation after installation.

Positioning and Fixation

• Accurately align the new starter with the mounting holes and place it in position slowly. Ensure the fitting surface of the starter is closely attached to the engine mounting surface with no gaps.

• Initially tighten the matching bolts by hand, then fasten the fixing bolts to 37N·m with a torque wrench. Control the force properly—over-tightening may damage threads, while under-tightening may cause the starter to loosen during operation.

Wiring Connection

• First connect the positive battery cable to the starter solenoid switch, then sequentially connect other electrical connectors and control wire harnesses. Ensure wire connectors match the corresponding terminals to avoid incorrect connections.

• Secure terminal 30 with a nut, controlling the tightening torque to 9.8N·m. If there is a wire harness bracket, install and fix it at a torque of 8.4N·m, then attach the wire harness clips to prevent wire harness wear.

• After completing the wiring, cover the terminal cover and organize the wire harnesses to avoid interference with the rotating parts of the engine.

Power-on Testing

• Reconnect the negative battery cable and ensure the connector is firmly attached.

• First perform a 12V no-load test, then a 24V no-load test. Observe whether the starter operates smoothly without abnormal noise.

• Then start the engine and check if the starter can smoothly drive the engine to start. The installation is qualified if there are no issues such as abnormal gear engagement or jamming.

Pre-installation Safety and Preparation

• Strict Power-off to Prevent Risks: Before installation, be sure to turn off the ignition switch, pull out the key, and disconnect the negative battery cable. This avoids local short circuits caused by the power supply wire touching the vehicle shell during installation, preventing damage to fuses and computer boards. This step is particularly critical for FAW models with computer-controlled engines.

• Verify Components and Clean: First, confirm that the new starter model is compatible with the FAW vehicle engine, with no external damage and complete components. At the same time, clean the mounting end faces of the engine and starter to remove rust and dirt; otherwise, it will lead to poor grounding and improper installation of the starter. Additionally, apply grease to the bearings and sliding parts of the starter to reduce friction during assembly.

• Do a Good Job in Protection and Tool Preparation: Lay a three-piece cover on the engine compartment fenders to avoid paint scratches during operation. Prepare intact tools such as a torque wrench and sockets to prevent damage to starter components due to tool issues.

Operational Specifications During Installation

• Prohibit Violent Assembly: If encountering tightly fitted components, do not forcibly strike them with tools such as hammers or wrenches. Use pulling or pressing auxiliary tools for separation or installation to prevent damage to key components such as the starter housing, internal windings, and gears.

• Bolt Tightening in Accordance with Standards: After aligning the starter with the mounting holes, initially tighten the bolts by hand, then fasten them with a torque wrench according to the specified torque. Avoid over-tightening (which may damage threads) or under-tightening (which may cause loosening during operation). Ensure the starter mounting surface is fully fitted with the engine mounting surface with no gaps.

• Orderly and Reliable Wiring Connection: First connect the positive battery cable to the solenoid switch, then sequentially connect other control wire harnesses to ensure one-to-one correspondence between wires and terminals. Tighten the wiring terminal nuts according to the specified torque, and fix the wire harnesses with clips to avoid contact with rotating engine components (such as belts and flywheels) that may cause wear and short circuits. In addition, derust and reshape oxidized or rusted wiring terminals, and replace them in a timely manner if severely damaged.

Post-installation Inspection and Usage Requirements

• Step-by-Step Testing: First reconnect the negative battery cable, then perform a 12V no-load test followed by a 24V no-load test. Observe whether the starter operates smoothly without abnormal noise. Subsequently, start the engine and check if the gear meshing is smooth. The installation is qualified only if there are no issues such as jamming.

• Standardized Startup Operation: Each startup time should not exceed 12 seconds, and the interval between two startups should be more than 1 minute. If startup fails three times in a row, stop operation and troubleshoot issues with the engine, battery, and circuits to prevent the starter from burning out due to overheating.

• Troubleshoot Hidden Dangers of Associated Components: If there is gear grinding noise during startup, check the meshing gap between the starter gear and the flywheel ring gear. If the flywheel teeth are severely worn, deformed, or deflected, replace the flywheel in a timely manner. At the same time, check the engine oil condition to prevent excessive engine startup resistance caused by abnormal oil, which may damage starter components.

References：

• PCauto: Its encyclopedia and other sections mention content such as disconnecting the battery ground cable before starter installation, performing a 12V no-load test first followed by a 24V no-load test for 24V starters, and standardized methods for cleaning specific components. These are highly consistent with the relevant installation steps and safety precautions.
• Autohome: The Q&A content on this platform details specifications such as bolt tightening torques for starter installation (e.g., 37N·m for mounting bolts, 9.8N·m for terminal 30 connecting nuts), 8.4N·m for wire harness bracket installation torque, as well as wiring sequence and prohibition of violent striking of components. All these align with the relevant installation details.
• Automotive Maintenance Platforms and Teaching Materials: Starter disassembly and assembly tutorials on maintenance platforms like Xiuchai 360, as well as teaching lesson plans related to automotive electrical equipment on Originality Documents, clarify requirements such as verifying component models before installation, applying grease to bearings and other parts, and conducting step-by-step tests after installation. These are important information sources for the relevant installation specifications and precautions.