There is a noise that occurs on engine start, immediately after releasing the key. I originally thought it was a loose timing chain, but I have checked that out and replaced the timing chain tensioner and upper guides. The upper guides were perfect, other than being brittle and breaking when I replaced them.

Now, I'm thinking it is more starter-related. Over the past year or so, occasionally when I would engage the starter, I would hear a whining noise followed by a short metallic grinding noise, like the Bendix came out but did not completely engage and turn the flywheel. I could retry it and it would start okay the second time. That only happened about once every few weeks.

Within the past month, I am now hearing a noise that sounds just like the noise this Bendix is making after it retracts away from the flywheel.

starter - YouTube

Is the Bendix a common failure point for these Bosch starters? Anyone else experience this?

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1993 400E, 256,000 miles (totaled)
1994 E420, 200,000+ miles
1995 E420, 201,000 miles

I changed the starter tonight with a Bosch re-manufactured unit.

FYI:There are two 4" long 10 mm Allen bolts holding the starter on (from back to front). In my case, I think they were installed by Satan himself. You will need a 24" extension (or two-12" extensions), a universal, and a 10 mm hex drive.

I tried it first with a 3/8" setup and I gave up trying to loosen the bolts after I twisted the breaker bar over 90 degrees and wondered when the extension would finally snap (and what part of my face it would hit when it did). I resorted to a 1/2" breaker bar, 1/2" drive 24" extension and 1/2" drive 10 mm hex. It took a lot of torque to finally break them loose but it did the job.

Also, there is a small Phillips head screw connecting one of the starter wires to the solenoid. It is difficult to get to with a screwdriver, but a Phillips head bit stuck into a 1/4" drive socket made it much easier. The large wire is secured by a 13 mm nut and is easy to get to. Be careful of the position of any shims that come off between the starter and bell housing.

When taking the old starter out, pay attention to how it finally slips through the steering damper/center link. It will make it much easier to get the new one in if you remember how the old one came out. You may even need to turn the steering wheel to fit it out from below. Most important, make sure you disconnect the battery.

Hopefully this will solve the noise problem.

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1993 400E, 256,000 miles (totaled)
1994 E420, 200,000+ miles
1995 E420, 201,000 miles

Tnx for the detailed explanation . . . but not clear on the outcome?

Since you replaced the starter . . did the noise stop??

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Regards . . . . JimF
-------------------
'94 S500 Cpe

Visit my Mercedes Web Page

I was afraid to speak too soon. Yes, the noise is gone. Thanks.

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1993 400E, 256,000 miles (totaled)
1994 E420, 200,000+ miles
1995 E420, 201,000 miles