Starter 0339501007 0399501006 0399501007 5801394025 STB9988AB for Iveco

Pre-Installation Preparation

1. Accessory and Tool Preparation

• First, verify that the 12V 2.2KW starter is compatible with the vehicle’s VIN. Prioritize original equipment manufacturer (OEM) accessories.

• Prepare tools including M12-sized compatible bolts, a new gasket between the starter and flywheel housing, a torque wrench, fine sandpaper, petroleum jelly, insulating tape, and a socket set. No special tools are required for this starter model—standard tools suffice for operation.

2. Safety and Environmental Preprocessing

• Park the vehicle on a level surface and turn off the engine. Disconnect the negative battery cable and wrap the terminal with insulating tape to prevent short circuits.

• For most Iveco models, this type of starter is located on the left side of the flywheel housing. If there are obstructing pipelines or wire harnesses nearby, gently organize and secure them. Label all connectors when disassembling obstructive components to avoid misconnection later.

• Meanwhile, use fine sandpaper to clean oil stains and rust from the mating surfaces of the starter and flywheel housing to ensure a tight fit during installation.

Core Installation Operations

1. Securing the Starter Body

• Replace the old gasket with a new one and place it on the mating surface between the flywheel housing and the starter—reusing old gaskets is prohibited.

• Precisely position the 12V 2.2KW starter in the mounting location and insert the M12×1.75-sized fixing bolts.

• Tighten the bolts to a torque of 86–105N·m using a torque wrench. Adopt a step-by-step diagonal tightening method to avoid housing deformation caused by uneven stress.

2. Wiring Handling, Connection, and Fastening

• First, polish the starter terminals with fine sandpaper to remove oxide layers, then apply a thin layer of petroleum jelly for rust prevention.

• Restore the electrical connections according to the labels: tighten the nuts for Terminal 30 and Terminal G to 20–30N·m, and the nut for Terminal 50 to 2–3N·m.

• Pay close attention to distinguishing wires during connection to avoid short circuits and starter damage due to incorrect wiring.

Finalization and Testing

1. Resetting Surrounding Components

• If pipelines, wire harness brackets, or other obstructive components were disassembled earlier, reinstall them in the reverse order of disassembly. Ensure all components are securely fastened and wire harnesses are neatly routed without compression.

2. Stepwise Power-On Testing

• Remove the insulating tape from the negative battery terminal and reconnect the cable.

• First, perform a no-load test: power on the system and observe the starter for smooth operation without abnormal noise.

• Then conduct an actual start test to confirm the starter can reliably crank the engine without issues such as weak cranking or jamming.

3. Final Inspection

• Check for no leakage at the starter gasket, no loose terminals, and that all wires are routed away from high-temperature engine components.

• Lightly touch the terminals to confirm no abnormal overheating. Once all installation steps are verified to comply with specifications, the entire installation process is complete.

I. Non-Negotiable Safety Operation Bottom Lines

1. Full-Cycle Power Disconnection Protocol

   Before disconnecting or connecting any wires, the negative battery terminal must be disconnected and wrapped with insulating tape. It is strictly prohibited to plug or unplug terminals or touch metal contacts while the power is on. The circuit of the Iveco starter is directly linked to the vehicle's ECU. Live-line operations may burn out core components such as the solenoid switch and ECU, and could even cause short circuits and fires.

2. Worksite and Protective Equipment Requirements

   Park the vehicle on a level surface and secure the wheels with wheel chocks to prevent rolling. Operations on slopes or soft ground are forbidden. Wait for the engine to cool down completely before installation to avoid burns from high-temperature components like the exhaust manifold. It is recommended to wear insulating gloves during operation to prevent electric shock or short circuits caused by direct hand contact with terminals.

3. Component Protection Taboos

   The starter itself is a precision electromagnetic component. Violent striking, prying, throwing, or severe impact are strictly prohibited, as these may cause displacement of the internal armature and gear set or damage to the coils. Do not pull the wire harness when connecting wires, to avoid damage to the insulation layer which could lead to short circuits.

II. Key Points for Accessory and Mounting Surface Compatibility

1. Inspection of Accessory Compliance

• Double-verify that the starter is compatible with the vehicle's VIN. Confirm that its model, power rating (12V 2.2KW), and the number and position of terminals match those of the original part. Priority should be given to genuine Iveco accessories. Non-genuine accessories must meet the ISO 6408 standard (with bolt strength class of at least 8.8).

• The gasket must be replaced with a new one. Genuine Iveco gaskets are made of oil-resistant rubber, and old gaskets are prone to aging and deformation, which may result in leakage. Using sealant instead of a gasket is strictly prohibited, as this may clog the ventilation holes of the flywheel housing.

• The fixing bolts must be of the M12×1.75 specification, and their length must match the installation depth (usually 35 - 40mm). Mixing short bolts or low-strength bolts is forbidden to prevent loosening and detachment after installation.

2. Specifications for Mounting Surface Treatment

• Thoroughly clean oil stains, rust, and residual old sealant from the mating surfaces of the flywheel housing and the starter using fine sandpaper. Ensure the surface is flat, dry, and free of protrusions or impurities; otherwise, poor sealing, vibration, and abnormal noise may occur.

• After polishing the terminals, wipe off any residual metal debris with a clean cloth. Prevent debris from falling into the interior of the starter, as this could cause gear jamming or coil short circuits.

III. Installation Precision and Torque Control

1. Mandatory Compliance with Torque Parameters

   All bolts and nuts must be tightened with a calibrated torque wrench. Relying on manual "feel" is strictly prohibited:

• Starter body fixing bolts: 86 - 105N·m. Tighten them diagonally in 2 - 3 steps. First pre-tighten to 40N·m, then gradually increase to the standard torque to avoid housing deformation.

• Nuts for Terminal 30 and Terminal G: 20 - 30N·m. Over-tightening may strip the threads of the terminals, while under-tightening can cause overheating and ablation. Iveco officially requires the use of a box-end wrench for tightening; adjustable wrenches are prohibited.

• Nut for Terminal 50: 2 - 3N·m. This terminal features fine threads, and over-tightening will damage the plastic base, resulting in failure of the solenoid switch.

1. Official Professional Maintenance Manuals for Iveco

• The manual explicitly states that the starter is located on the left side of the flywheel housing;

• Specifies the fixing bolt size as M12×1.75 and the tightening torque as 86–105N·m;

• Defines the tightening torque for Terminal 30 and Terminal G as 20–30N·m, and for Terminal 50 as 2–3N·m;

• Requires replacing the gasket with a new one and applying a thin layer of petroleum jelly to the terminals for rust prevention.

2. Practical Experience and Universal Standards from Automotive Repair Platforms