Installation of 12V 1.1KW GAC Trumpchi Starter

Preliminary Preparations

1. Tool Preparation: Equip with suitable wrenches (10mm, 12mm, etc.), sockets, Phillips screwdrivers, and a torque wrench. Meanwhile, wear gloves and goggles to avoid injuries during operation.

2. New Starter Verification: Confirm that the 12V 1.1KW specifications match the vehicle. Inspect the new starter for no external cracks, complete components, and normal internal parts such as brushes and solenoid switches.

3. Safe Power Disconnection: Open the engine compartment and disconnect the negative battery cable with a wrench to prevent short circuits during installation.

Old Starter Removal

1. Locate the Starter: For GAC Trumpchi models, the starter is mostly located at the lower right rear or lower left rear of the engine, near the junction of the engine and transmission. After locating it, clean dust and oil from the surrounding surface.

2. Disconnect Wiring: First, separate the wiring harness clips on the starter, remove the wiring harness bracket bolts, open the terminal cover, loosen the fixing nut of terminal 30 and disconnect the connecting wire, then pull out the starter's electrical connector. Avoid pulling the wires during operation.

3. Remove the Old Starter: Use appropriate tools to loosen the two fixing bolts of the starter, then smoothly take out the old starter.

New Starter Installation

1. Clean the Mounting Surface: Wipe the contact surface of the starter mounting base with clean cotton yarn to remove oil and rust, ensuring the mounting surface is flat to prevent the starter from loosening after installation.

2. Fix the Starter: Align the new starter with the mounting holes and place it smoothly. Temporarily fasten it with two bolts, then use a torque wrench to tighten the bolts to 37N·m to ensure the starter is secure without wobbling.

3. Restore Wiring Connections: First, connect the electrical connector, then fasten terminal 30 with a nut to 9.8N·m. Next, close the terminal cover, install the wiring harness bracket and tighten the bolts to 8.4N·m, and finally reinstall the two wiring harness clips.

Precautions for Installation of 12V 1.1KW GAC Trumpchi Starter

I. Safety Operation Category

1. Mandatory Power Disconnection Specifications: Before installation, the negative battery cable must be disconnected and a waiting period of at least 5 minutes observed (to discharge residual circuit power). Live operation of wiring or fixing bolts is strictly prohibited to avoid short circuits that may burn the starter solenoid switch, wiring harness terminals, or cause electric shock hazards.

2. Protective Equipment Wearing: Wear insulated gloves and goggles throughout the operation. Avoid direct contact with wiring terminals with bare hands (to prevent oxide layers from affecting conductivity) and prevent oil stains or metal debris from entering the starter interior.

3. No Open Flames and Oil Stain Prevention: Smoking and open flames are strictly prohibited in the installation area. The starter surface and mounting base must be kept dry and clean to avoid residual flammable liquids such as gasoline or engine oil (electric sparks may be generated during 12V circuit startup, leading to fires).

II. Installation Precision Category

1. Mounting Surface Cleaning Requirements: Thoroughly remove oil stains, rust, and metal debris from the starter mounting base and engine connection surface to ensure tight and flat fitting. If the mounting surface is deformed, it must be corrected first (otherwise, it will cause starter operation jitter and abnormal gear meshing).

2. Bolt Tightening Standards:

• The two fixing bolts of the starter must be evenly tightened diagonally to a torque of 37N·m±2N·m. Over-loosening (resulting in loose noise during operation) or over-tightening (causing thread damage or mounting base deformation) is strictly prohibited.

• The tightening torque for the wiring terminal nut (Terminal 30) is 9.8N·m±1N·m, and for the wiring harness bracket bolt is 8.4N·m±1N·m. A torque wrench must be used for precise control to avoid terminal loosening, overheating, or wiring harness damage.

3. Gear Meshing Inspection: After installation, manually rotate the starter drive gear to ensure flexible extension and retraction without jamming or sticking. If the meshing gap between the gear and the engine flywheel ring gear is too small (due to installation deviation), adjust the starter position to prevent gear impact and wear during startup.

III. Wiring Connection Category

1. Terminal Contact Requirements: When connecting Terminal 30 (main power terminal), polish the oxide layer on the terminal surface to ensure tight contact between the terminal post and nut without loosening or poor contact (otherwise, it will cause weak startup or terminal overheating and ablation). Do not clamp the terminal forcefully with pliers to avoid terminal deformation.

2. Wiring Harness Routing Specifications: When restoring the wiring harness, fix it according to the original vehicle's clip positions. Avoid wrapping the wiring harness around the starter housing or high-temperature engine components (such as exhaust manifolds and turbochargers) to prevent the harness from being scorched by high temperatures or damaged by friction during operation.

3. Connector Foolproof Design: The electrical connector features a foolproof structure. Align it with the clip direction and insert smoothly until a "click" sound confirms locking. Violent insertion or removal is strictly prohibited (it may damage connector pins and cause the starter to be unresponsive).

IV. Component Protection Category

1. Prohibition of Violent Operation: Do not strike the starter housing, drive gear, or solenoid switch violently to avoid bending of the internal armature shaft, brush detachment, or damage to the field winding. Install the starter smoothly into the mounting hole without tilting or forcing it.

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References：

Practical Experience in General Starter Installation

• The torque parameters such as 37N・m for the starter fixing bolts and 9.8N・m for the Terminal 30 nut mentioned in the disassembly and installation tutorials on Dongchedi (懂车帝) are completely consistent with the torque standards in the answer;

• The maintenance Q&A section on Autohome (汽车之家) clearly specifies key points such as prohibiting violent striking during disassembly and assembly, and using gasoline-damped (wringed dry) cotton yarn to clean internal components, which aligns with the component protection precautions in the answer;

• PCauto (太平洋汽车) also mentions checking the starter model before installation and testing its working status after installation, which is consistent with the preliminary preparation and final testing requirements in the answer.

  In addition, Bangshou Auto Parts Network (帮手汽配网) notes that the starter of GAC Trumpchi models is mostly located at the lower right rear or lower left rear of the engine, which confirms the positioning description of the starter in the answer.

Reference Standards and Specifications Mentioned in the Text