Changing the starter motor in your Chevrolet Astro van may become necessary if the starter starts to grind or function intermittently. Removal of the starter allows you to take it to an auto-parts store and have it bench-tested. Most stores will do it for free and it is the best way to be sure you need a new starter. New or rebuilt starters are available for the Chevrolet Astro and most carry about the same warranty. If you want to save a large amount of money, a used starter may be available from a salvage yard.
Tools Used: Socket set, Ratchet, Jack, Jack stands, Wrench set, Torque wrench
Change the Starter
Open the hood of your Astro van and disconnect the negative battery cable from the battery. Use a wrench to loosen the retaining bolt on the cable end, then remove the cable from the terminal.
Place a jack under the front of the van and lift it high enough to work under comfortably. Position a set of jack stands under the frame to support it and keep it secure while you are under it.
Locate the starter on the passenger's side of the engine, near the back. You will not be able to disconnect the wiring with the starter still on the engine, so removal has to be done first.
Locate the two starter-motor mounting bolts near the nose of the starter. They run through the starter from the bottom and into the block. Remove the bolts with a socket and ratchet, being careful not to drop the starter.
Lower the starter out of the frame and remove the two nuts from the back of the starter solenoid with a wrench, then lower the starter to the ground. Move the old starter out from under the van and position the new one under the van. Raise the starter high enough to connect the wiring-harness connection on the back of the starter solenoid.
Connect the large wire with the larger connector to the "B" terminal on the solenoid. The terminal is market next to the terminal in the plastic of the starter solenoid. Connect the other two wires to the "S" terminal on the starter solenoid. Tighten the nuts on both terminals with a wrench.
Raise the starter into position on the engine and install the two starter retaining bolts. Tighten them with a socket and ratchet, then torque the bolts to 31 ft-lbs. with a torque wrench.
Raise the front of your Astro off the jack stands with a jack and remove the stands from under the van. Lower the jack, setting the van back on its wheels.
Connect the negative battery cable to the negative battery terminal and install the retaining bolt. Tighten the bolt with a wrench.
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