Installation Method for 12V 1kW Starter of Changan Automobile

Preparation and Safety

1. Vehicle Preparation: Turn off the engine, engage the handbrake and shift to P/N gear; perform operations when the vehicle is cool, and keep away from high-temperature and rotating components.

2. Power-off Operation: Disconnect the negative terminal of the storage battery and insulate it to prevent accidental start-up and short circuit.

3. Tools: Socket/wrench (common specifications: 10/12/14/17/19mm), torque wrench, brush/cleaning agent, copper paste/high-temperature resistant grease, insulating tape, cable ties.

4. Spare Parts: Verify that the starter model matches the vehicle, with intact appearance and free movement of the pinion gear and clutch without jamming; check the mounting holes and terminal markings (B+/30, S/50).

5. Space Preparation: Remove obstructive components such as intake manifold, air filter box and guard plate; take photos to record the installation position of the old starter and wiring harness routing for easy reassembly.

Installation Steps (Reverse Sequence of Disassembly)

1. Cleaning and Positioning: Thoroughly clean oil stains, rust and impurities on the joint surface of the engine and transmission to ensure a flat mounting surface; apply a small amount of grease to the drive end of the new starter to ensure smooth expansion and retraction of the pinion gear.

2. Positioning and Fastening: Align the starter with the mounting holes, insert the fixing bolts, screw them into place by hand, then tighten them with a torque wrench according to the manufacturer’s specified value (common range: 18–25 N·m, subject to the vehicle service manual). Avoid over-tightening (which may cause deformation) or under-tightening (which may lead to abnormal noise).

3. Electrical Connection (Follow the sequence of thin wires first, thick wires second; control circuit first, power circuit second):

• Control Wire (S/50): Fully insert the plug or tighten the small nut to ensure good contact without looseness.

• Power Wire (B+/30): Connect the thick positive wire of the storage battery to the main terminal of the starter, tighten the nut with a lock washer; apply a small amount of petroleum jelly or copper paste to the terminal to prevent oxidation.

• Grounding: The starter housing is grounded to the engine/vehicle body via mounting bolts. If a separate grounding wire is provided, fasten it securely as well.

4. Power Restoration and Testing:

• Check that the wiring harness has no interference or insulation damage, and secure it with cable ties; reconnect the negative terminal of the storage battery.

• No-load Test: Turn the key to the START position. The starter should run smoothly without abnormal noise, and the pinion gear should retract quickly when the key is released.

• Vehicle Start-up Test: Perform cold/hot start-up multiple times to confirm strong starting performance, no gear striking or slipping, and normal voltage displayed on the instrument panel.

5. Reassembly: Refit the removed obstructive components (air filter/guard plate, etc.), and clean up tools and the working area.

Reference for Common Vehicle Models (Changan Series)

1. Mini-cars such as Benben Mini: Generally equipped with 2 fixing bolts. The terminals of the solenoid switch are marked as B+ and S respectively, and reassembly can be carried out in reverse sequence.

2. SUVs such as CS35/CS75: It may be necessary to remove the lower section of the intake manifold/guard plate. After installation, ensure the intake system and pipelines are fully restored to avoid air leakage and illumination of malfunction indicator light.

Key Precautions for Installation of 12V 1kW Starter of Changan Automobile

1. Power-off Operation Must Be Performed FirstPrior to installation, disconnect the negative cable of the storage battery and wrap the connector with insulating tape to prevent short circuit, electric arc burns or accidental starter activation caused by unintended power-on. Live operation on terminals is strictly prohibited throughout the process.
2. Cleanliness of Mounting Surface and Positioning Accuracy

• Thoroughly remove oil stains, rust and impurities from the joint surface between the engine and the starter. Otherwise, excessive mounting clearance will occur, leading to abnormal starting noise or bolt loosening.

• Align the starter with the mounting holes accurately during positioning. Never strike the starter housing forcibly, so as to avoid damage to the solenoid switch and gear set.

3. Bolt Fastening in Strict Accordance with Torque Specifications

• Tighten the fixing bolts with a torque wrench. The recommended torque value ranges from 18–25 N·m (specific value shall comply with the service manual of the corresponding vehicle model).

• Over-tightening will cause deformation of the starter housing and damage to bearings; under-tightening will induce resonance and abnormal noise, or even bolt detachment which may damage the flywheel ring gear.

• Tighten the bolts diagonally and in stages to ensure uniform stress distribution.

4. Standard Electrical Connection (Core Anti-fault Requirements)

• Wiring Sequence: Connect the control wire (S/50 terminal) first, then the main power wire (B+/30 terminal); reverse the sequence when disconnecting the wires.

• Install a lock washer on the main power wire connector. After tightening, apply a small amount of copper paste or petroleum jelly to the terminal surface to prevent oxidation and ablation.

• Fully insert the control wire plug to ensure no loosening or poor contact; do not twist or pull the wiring harness to avoid insulation damage and short circuit.

• The starter housing is grounded through the mounting bolts and the engine block. Poor grounding will result in weak starting and overheating. Ensure that there is no paint or rust on the joint surface.

5. Prevention of Gear Striking and Inspection of Gear Retraction

6. Before installation, manually push the starter pinion gear to confirm that it can extend and retract freely without jamming of the return spring; inspect the flywheel ring gear for severe wear or missing teeth.

   During no-load test, turn the key to the START position. After the starter operates, release the key—the pinion gear must retract quickly and completely. If not, inspect the solenoid switch or the return spring.

   If gear striking noise occurs during vehicle start-up, stop the engine immediately and inspect the following: whether the starter mounting angle is offset, whether the flywheel ring gear is damaged, and whether the meshing clearance between the pinion gear and the ring gear is normal.

   Prevention of Interference Between Wiring Harness and Surrounding Components

   After wiring, arrange the wiring harness and secure it with cable ties at positions away from high-temperature engine components (e.g., exhaust pipe) and rotating components (e.g., pulley), so as to avoid harness aging and short circuit caused by abrasion and high-temperature baking.

   When reinstalling obstructive components such as the intake manifold and guard plate, ensure that the wiring harness is not squeezed, and that the pipeline connections are sealed tightly to prevent air leakage and illumination of the engine malfunction indicator light.

   Step-by-Step Verification in Testing Phase

   Conduct the no-load test first: After restoring power, start the starter briefly (no more than 5 seconds). The starter should run smoothly without abnormal noise, and no obvious voltage drop should be observed.

   Then perform the vehicle start-up test: Conduct cold and hot start-up 2–3 times respectively. Confirm that the start-up is powerful without slipping or abnormal noise, and that the voltage displayed on the instrument panel is normal.

   The duration of a single start-up shall not exceed 10 seconds, and the interval between two consecutive starts shall be at least 30 seconds to prevent starter burnout due to overheating.

   
   
   
   

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Supplementary Notes

1. Content Nature

   This is an integrated practical solution combining universal standards and vehicle-specific adaptations. It incorporates industry-wide general specifications such as power-off safety protocols, torque control requirements, wiring sequence rules, and gear-striking prevention measures. Meanwhile, it is tailored to the disassembly/assembly space constraints and component characteristics of common Changan models (including mini-cars and SUVs) to facilitate on-site implementation.
2. Official Reference Basis

   For the starter installation specifications and torque values of various Changan vehicle models, the official Service Manual corresponding to the specific model year shall prevail (e.g., the dedicated chapters for Benben MINI, CS35, CS75, etc.). The torque range of 18–25 N·m provided in this guide is a common reference value, intended only for quick on-site verification. For formal maintenance operations, always consult the official service manual for confirmation.
3. Recommendation for Precise Reference

   If you require the original official manual (including links or screenshots) for a specific Changan vehicle model, please provide the exact model and production year. I will assist you in locating the relevant resources and clearly marking their official sources.