How do to replace the starter on a 1989 through 2002 Isuzu Rodeo Amigo or 4WD Honda Passport with a V6 engine?

Answer 1

Answer number 1Easier done than said! Don't be intimidated by the complexity of this job. You can save hundreds of dollars by doing this simple task in you driveway or garage. This is one of the easier replacements that I have done on a 4WD but there needs to be a little preparation. Exhaust pipe doesn't need to be removed for the 2WD model.

Tools required:

For the removal of the exhaust pipe form the exhaust manifold

17 mm deep well Impact socket

½ in drive 12 in extension for socket and ratchet

½ in drive breaker bad/ratchet w/12 in extension

½ in drive swivel for the socket

For the removal of the exhaust pipe a the flange

Reciprocating saw w/metal cutting blade

For the removal of the starter

Assorted sockets and wrenches for other bolts and nuts

Floor jack and 2 jack stands

Parts needed:

Exhaust Manifold-to-pipe crushable gasket

High Temp caulking for the exhaust pipe flange gasket.

Starter

2 Bolts, nuts and washers for the exhaust pipe flange

Procedure:

Jack the front of the vehicles and place on the jack stands. Take the battery terminal off. Get up under the vehicles and spray WD-40 on the 3 nuts that hold the exhaust pipe on the exhaust manifold and on the 02 sensor that is just below them. Let this sit overnight for breaking purposes. Next day, remove the 02 sensor and using the 17 mm deep well socket, 12 in extension and breaker bar, remove the 3 nuts that were sprayed the night before. This should take about 3 minutes and a little "elbow grease". There is no need in removing the second 02 sensor but it does need to be unplugged at the connector just above it. Next locate the flange about 4 feet aft of the loosened manifold and using the Reciprocating saw, cut the welded on nuts from the back of the flange that is holding the bolts on. Retain the metal gasket for reuse. This should take about 5 minutes. The loose pipe should be free to move a limited space but it will be enough to get the starter out of the hole that it is in. Remove the aluminum shield from below the area where the starter is and remove the 2 bolts holding the starter on. Drop it down where you can remove the cable and small plastic connector next to it. The starter should come out of the confined space that it is in. You will simply go back in reverse order to replace the starter. Ensure that a new gasket is used with the exhaust manifold and 2 good beads of High Temp caulking is used on the rear flange gasket.

I suspect that the different models have varying degrees of difficulty. On 1998 Amigo 2.2, the bottom bolt can only be accessed by somebody with very small hands and the top bolt appears to be inaccessible. Answer #2 (massive pain) does apply to some models.

Answer number 2Remove starter on a 1999 rodeo 3.2 v6 first this is no easy task you will need torches and air tools unless you really have ALOT OF PATIENCE ! Disconnect the + red post on battery. Jack up left side (DRIVER SIDE) secure vehicle with stands or blocking ! Spray the 3 bolts mounting the exhaust pipe to the manifold with a good pentrating oil.Unplug the 2 oxy. sensors on the pipe you'll be removing ( be careful not to break the clips on them) Get a thin sheet of metal cut it to fit up in front of fuel tank so no sparks can get on tank (GET A FULL FIRE EXTINGUISHER)( if you have a fuel leak you have to take care of that first!) after confiming there is no fuel or other combustibles in the area torch off the weld nuts on the rear side of the flanged pipe be careful not to damage flanges take a hammer and drive out bolts. Now move to the front of pipe room is limited i used several 3/8 drive extensions a swivel, 17 mm deep well 6 point socket with a 3/8 to 1/2 adapter hooked up to a 1/2 breaker bar.These nuts are selflocking tight little Bas*#% glow them with the torch be careful that the heat from your flame doesn't burn any wires or hoses! Key here is BABY STEPS heat it turn it heat it turn it after a full turn has been made heat it and hit it with the air rachet. You can now move the pipe down and back far enough to remove starter.Remove the 2 10mm bolts holding on shield. Remove the 2 14mm bolts holding starter to eng.for one you must slide wire loom out of the way to get on it. The starter wires one wire you must push down on top of connector to release it. the other wire is a 13mm i believe. Starter is gonna run about $150.00 Check gasket and flange area at manifold & gasket at flange at rear pipe. I applied red high heat silicone and reused mine. Used new nuts (Couldn't find flanged lockers just used regular mm nuts no washers) and bolts with neversieze. This should be done by a profesional ! LOL!

Answer #3 From LC Campbell

How do you remove the starter on a 2001 3.2 v-6 DOC engine in a Rodeo. First of all it's not fun but take it from someone who has accomplished the task that is can be done. Most of the information above (#2) is good stuff, however I'd like to add some service helps.

1) When you look at the starter from under the car you will scratch your head and want to simply give up as it looks like the engineers installed it then put the engine into the car and that was all that was considered.

2) The space to remove the starter through is very small (too small) so you have to remove 3 head pipe bolts with a deep socket 17mm. Then remove all of the bolts on the next joint down pipe at the next flange. YOU DO NOT HAVE TO REMOVE THE HEAD PIPEsimply use a clamp like a ratcheting wood "C" type clamp and force the head pipe against the left or Port frame--right against it.

Be sure you have disconnected the battery terminals for safety and this is a must !!

3) Access through the rubber skirting just above the left front wheel the main starter wire by removing the nut. Also through the same access remove the clip type connector which is the ignition feed.

3.5) Some say you have to remove the Oxy sensor...I found that I did not but I had to watch not to strain the wire that goes to it.

4) Remove two long bolts from the under side of the starter (universal will be needed for the inboard bolt).

5) Pull the starter to the front of the vehicle which will disengage it from the mounting and flywheel.

6) I actually turned the starter to allow the removal butt first. Important--as you find the position that will allow you to remove the starter through the narrow hole I marked the radial position of the starter with an indelible pin so as to make it easier to reinstall.

7) The starter is completely serviceable if you can find the parts. Most want you to buy a new starter which is in access of $300.00 from the dealer. I was able to disassemble the Bendix and clean up the armature contactor with a moto tool and small wire brush. I also cleaned up and put silicone grease on the o-rings for re-assembley.

8) You will also need a new crushable gasket for the head pipe to exhaust manifold and you may need a gasket to the next flange down stream...I was able to use some red-silicone because my gasket was not damaged.

Another little trick I used was to use a 10"X1/2" dowel which I had glued some emery paper to and cut to round like the dowel. All of this effort was to make it easier to start the inboard mounting bolt on the starter X 2ea. One could also remove a small bolt on the bell housing cover plate which is in the way to accomplish the same thing.

It's hard but it can be done. lc