Bosch starter motor wiring ID

[Porkchop]

Hi chaps, I've just replaced the Bosch starter motor in my 1984 240 Estate with a reconditioned Bosch from a 1988 model 240. Apart from the starter being a pain in the arse to get out and reinstall, the wiring connections are different on the replacement starter. Previously I had two male spade connectors on the back of the solenoid, two joined blue/yellow wires went to the lower spade and two joined brown wires to the upper(smaller) spade.

The replacement unit has three full-sized connectors arranged differently (one to the engine side and two to the outer side, this is the older one: https://imgbox.com/D6GGSORL

And this is the new later model Bosch: https://imgbox.com/f216kfxQ

Any info would be great, I find auto electrics a bit daunting!

[morwenna240]

In Haynes manual at back is a set of wiring diagrams for all models. Have a look at both model yrs, u should be able to figure it out. Though the diagrams do look daunting to an unwilling eye, a patient perusal will reveal the info.

[Clan]

Originally Posted by Porkchop

Hi chaps, I've just replaced the Bosch starter motor in my 1984 240 Estate with a reconditioned Bosch from a 1988 model 240. Apart from the starter being a pain in the arse to get out and reinstall, the wiring connections are different on the replacement starter. Previously I had two male spade connectors on the back of the solenoid, two joined blue/yellow wires went to the lower spade and two joined brown wires to the upper(smaller) spade.

The replacement unit has three full-sized connectors arranged differently (one to the engine side and two to the outer side, this is the older one: https://imgbox.com/D6GGSORL

And this is the new later model Bosch: https://imgbox.com/f216kfxQ

Any info would be great, I find auto electrics a bit daunting!

you still have 2 extra spade connectors , its just that one of them is a dual tag... firstly put just the blue/yellow one on a tag, if it works it is the correct tag and put the brown on the other tag.. If it doesn't work swap the blue/yellow to the other tag and put the brown one on the spare tag left over. why is there a blue wire on the body of the starter and where does it go?

[Porkchop]

Thanks Clan, Basically did exactly as suggested (I'm in Australia so time differences come into play) before seeing this post and the old girl fired up. Wouldn't run though, Ozvolvo forum suggested ballast resistance bypass which allowed the engine to run along nicely, seems like I'm in need of a new ballast....

[Clan]

Originally Posted by Porkchop

Thanks Clan, Basically did exactly as suggested (I'm in Australia so time differences come into play) before seeing this post and the old girl fired up. Wouldn't run though, Ozvolvo forum suggested ballast resistance bypass which allowed the engine to run along nicely, seems like I'm in need of a new ballast....

Have you got 2 ballast resistors? measure the resistance with an ohm meter the Ohm rating is marked on them it will be a low figure less than 5 ohms . I doubt one of those those is faulty unless it is corroded.