Installation Method for 12V 1.2KW Starter of Great Wall F3

I. Pre-installation Preparation

Tool Preparation

• Special Tools: Socket wrench (10mm, 12mm, 14mm), torque wrench, Phillips screwdriver, combination pliers, insulating gloves, multimeter.

• Auxiliary Materials: Lock washer, medium-strength thread locker (e.g. Loctite 242), cleaning cloth, rust inhibitor.

Safety Preparation

1. Turn off the engine, disconnect the negative battery cable, and wait for 10–15 minutes to ensure the circuit is fully discharged and prevent short circuits.

2. Lift the vehicle steadily with a jack and secure it with safety stands. Never perform operations with the vehicle supported only by a jack.

3. Clean oil stains and dust in the starter installation area, and check the flywheel ring gear for wear or fracture.

Accessory Inspection

1. Confirm that the starter to be installed is 12V 1.2KW and matches the engine model of the Great Wall F3 (it is recommended to verify the accessory part number).

2. Check that the starter solenoid switch, drive gear and wiring terminals are intact without rust or deformation.

II. Installation Steps

1. Locate the Starter Installation Position

2. Pre-install the Drive Gear and Guide Alignment

1. Manually pull out the starter drive gear and align it with the tooth gaps of the engine flywheel ring gear to ensure smooth gear meshing without jamming.

2. Fit the starter to the mounting surface and adjust the angle to fully align the mounting bolt holes.

3. Fasten the Mounting Bolts

1. Insert the lock washers in sequence, screw in the two mounting bolts, and hand-tighten them until they fit snugly to avoid misalignment.

2. Use a torque wrench to tighten the two bolts evenly in a crisscross pattern according to the torque standard of 25–30N·m (tighten one bolt halfway first, then the other, and repeat the operation until the specified torque is reached).

3. Apply a small amount of medium-strength thread locker to the bolt threads to prevent loosening during vehicle operation.

4. Connect the Electrical Circuits

1. Main Power Cable Connection: Connect the terminal of the thick positive battery cable to the main terminal (marked "+" or "B") on the starter solenoid switch. Tighten the nut with a 14mm socket and control the torque within 12–15N·m.

2. Control Wire Connection: Connect the terminal of the thin control wire in the engine wiring harness to the auxiliary terminal (marked "S") of the solenoid switch. Tighten the fixing nut to ensure a secure and non-loose connection.

3. Inspect all wiring terminals to ensure no exposed wires (to avoid short circuits). Organize the wiring harness with cable ties to prevent contact with high-temperature or moving parts of the engine.

5. Reconnect the Battery

III. Post-installation Testing

1. No-load Test: Shift the transmission to neutral (for manual transmission) or Park (P) gear (for automatic transmission), press the clutch pedal (for manual transmission), turn the ignition switch to the "Start" position. Observe whether the starter runs smoothly without abnormal noise and the drive gear extends and retracts normally.

2. Load Test: Start the engine and check that the starter operates with sufficient power without slipping or gear jamming. Ensure the drive gear retracts quickly after the engine starts.

3. Re-inspection: After turning off the engine, recheck that the mounting bolts and wiring terminals are secure, and there is no oil leakage on the starter surface.

Precautions for Installation of 12V 1.2KW Starter of Great Wall F3

I. Electrical Safety Precautions

Power-off Operation is a Prerequisite

Strictly Prohibit Reverse Connection of Circuits

• The main power cable (thick cable) must be connected to the main terminal (marked "+" or "B") of the starter solenoid switch, and the control wire (thin wire) must be connected to the auxiliary terminal (marked "S")—they must not be confused.

• Reverse connection of circuits will directly burn out the solenoid switch coil and even cause instantaneous discharge and overheating of the battery.

Terminal Fastening and Insulation Protection

• Tighten the wiring terminal nuts to a torque of 12–15N·m. Loose fastening will lead to poor contact, overheating and ablation; excessive fastening may cause thread slipping or terminal breakage.

• Ensure that all wires have no exposed metal parts. After installation, wrap the edges of terminals with insulating tape to avoid contact with metal components of the engine and prevent short circuits.

Wiring Harness Arrangement to Prevent Interference

II. Mechanical Installation Precautions

Cleaning and Leveling of Mounting Surface

• Thoroughly clean oil stains, rust and sealant residues on the contact surface between the engine cylinder block and the starter before installation to ensure tight fit.

• If the mounting surface is deformed or pitted, it must be repaired first. Otherwise, the starter housing will be subjected to uneven stress, resulting in severe vibration during operation and damage to bearings and gears.

Gear Meshing Inspection

• Manually pull out the starter drive gear, align it with the tooth gaps of the flywheel ring gear, and rotate the gear to check for smooth meshing without jamming or tooth jamming.

• If the flywheel ring gear is severely worn, has missing teeth or tooth surface peeling, it must be replaced first. Otherwise, the starter may slip and produce abnormal noise during startup, or even damage the drive gear.

Bolt Fastening Specifications

• Install lock washers on the mounting bolts and apply medium-strength thread locker (e.g. Loctite 242) to prevent loosening due to vehicle vibration during operation.

• Tighten the two mounting bolts evenly in a crisscross pattern, with the torque strictly controlled within 25–30N·m. It is strictly prohibited to fully tighten a single bolt at one time; otherwise, the starter housing may be deformed.

Avoid Hard Hammering

III. Testing and Usage Precautions

No-load Test Specifications

• During the no-load test, shift the transmission to neutral (for manual transmission) or Park (P) gear (for automatic transmission), press the clutch pedal (for manual transmission), turn the ignition switch to the "Start" position. The duration of a single test shall not exceed 5 seconds, and the interval between two tests shall be at least 1 minute to prevent overheating and burnout of the starter.

• Observe whether the starter runs smoothly, the drive gear extends and retracts flexibly without "clacking" abnormal noise.

Load Test Precautions

• When starting the engine, if the starter runs at low speed with insufficient power, or abnormal meshing noise occurs between the drive gear and the flywheel ring gear, stop starting immediately and check the battery voltage, circuit connections and gear meshing status.

• After the engine starts, confirm that the drive gear can retract quickly. If the gear jams and fails to retract, disconnect the negative battery cable immediately and disassemble to inspect the one-way clutch.

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