well... got the starter out. got some help from:
viewtopic.php?f=1&t=7693
but there should be some more info.
1.
Start from above. REMOVE THE CABLES TO THE BATTERY! I forgot that once and almost sh*t myself changing starter on a 205gti!
2. remove heatshield from the forward exhaust manifold. 5 size 10 bolts. be careful... old bolts on exhaust parts tend to be rusty and/or fragile
3.
Get under the car. remove protection plate below engine
4.
Stand up in front of the car. first release the two lambda contacts... one green and one blue. just follow the cables.
Get under the car. remove the exhaust clamp below the engine. I used a reciprocating saw (blame google translate if thats the wrong name for it in english) because they are usually totally rusted and nearly always break with a couple of bloody knuckles as a result so buying a new one before you begin is a good idea.
Stand up in front of the car. loosen the three top bolts holding the exhaust manifold and downpipe together. I use an impact screw driver and a small sledge hammer to loosen them a little and then a long power shaft (directly translated from swedish... 50cm handle) with six point socket size 13 (i always use 6 point sockets when I work with exhaust bolts and nuts because the tend to have rusted away som and a 12 point usually totally destroying them). again be careful with rusty nuts.
Get under the car. Drop the downpipe and remove it.
5. loosen the two size 10 bolts holding the little heatshield in front of the starter. can be a little fiddly to get out.
6. loosen the three size 16 bolts holding the starter in place.
7. now the fun part... try to loosen the size 13 nut holding the positive cable and the size 8 nut holding the thin cable to the solenoid. be careful turning it not to damage the thin cable or the cable lug to the solenoid. Then turn and gently lower the starter. It wasnt that difficult once the downpipe is off.
all in all not that big a deal (although it was quite cold outside). I was quite nervous since I once changed the wires to the gear linkage on my mothers worthless 605 v6... insane construction... thought the whole car was worthless. stupid solutions in several places. I know it share some things with 406, like the brakes, but I think 406 is a very good car. Ive got nr 2 and 3 now after selling our green metallic 194hp v6 with light leather when we got our second child. 210hp station wagon was the way to go and a 2.0 turbo for 8000 swedish kronor with broken spring (and that is the most stupid thing with this model... all my cars have had springs breaking falling down on the brake hose... idiotic construction making the spring narrower in the top and bottom. we´ll see if the HR springs are made of better quality. changing the top mount bearings reguarly is a must on these cars not to twist the spring apart).
The starter turns and work when I use jumper cables to test it. Gonna see if theres any current to the solenoid cable when my wife gets home from work. I will take it to our local bosch work shop to test it and buy new cole and clean the collector (correct word in english?) if its possible.
Jasper5:
I live in the south of sweden... I can see denmark if i drive to the coast 20 min away so your son would probably stay inside today with a varm cup of tea instead of crawling around in the snow and cold outside considering he lives in Gävleborg.
edit: made some things easier to understand if someone else gonna do this in the future
