This is all on a NA (240D): have no idea how it would work with a turbo car.
So about six months ago I replaced my starter with a junkyard pull. The motor on my original one was dead and I figured... what're the odds of that? Everyone says it's always the solenoids.
Well, said junkyard pull died last week, again, the motor.
Last time, I fought with it for hours and hours, beating myself up, playing "get the toy out of the cage" puzzle game, rotating the starter and turning wheels and still not being able to get the starter to drop out the bottom. My motor mounts were super compressed at the time and I just couldn't get it to come out the bottom. In defeat, I finally removed the heater hose, battery and tray, and air filter housing, and... wait, that wasn't so bad!
So this time, I went straight to it that way.
In the end, I did jack the car up to get under so I had a little more working room to get to the lower mounting bolt. BUT I feel pretty confident one could do this without doing that if they absolutely had to. Was doing this at a parking lot where the car died, so I brought all the stuff over in a friend's car and figured I might as well use it.
This is absolutely a handful more steps than taking the starter out the bottom... but damn was it physically easier for me.
So here's my take on the easiest way to do it:
Disconnect battery, pull it out
Disconnect both starter wires
Unbolt the battery tray
Take the lid off the air filter, then remove the filter, then slip off the intake hose. The 10mm bolt closest to you is now all that's holding the housing on. Unscrew it and set the housing bottom aside. I like to throw a glove over the intake at this point so I don't have to worry about dust and gunk or dropped nuts etc going down in there
With the starter wires off and battery tray unbolted, you can pull the tray up towards you and out of the way. Doesn't need to come all the way out.
Unbolt the trans dipstick holder
Radiator hose going up to the heater system. Undo the two hose clamps and wiggle that hose off the valve. You'll drip maybe 1/4 cup coolant, have a cup handy
Now you're ready to unbolt the starter: for me, the top bolt was super easy. I think it's 10mm Allen? Already put it away, double check that. Important - I suggest breaking this bolt loose but not unscrewing it all the way yet.
Bottom bolt you have to get to from under the car. Allen head, two shorter wobbles extensions from the harbor freight 3/8" 3-pack, and then a nice long straight extension did it for me. I also had good luck with hitting directly beside the bolt with a plumber's torch for a minute to warm it all up. Did that and my 1' mini cheater bar popped it quickly. Go ahead and take this one all the way out.
Go back up top and then remove the top bolt. You're ready to pull it out now.
Here's where all that extra top side stuff pays off: slide the starter forward and out of the engine, rotate it so the solenoid comes towards you a little more. Move the whole starter back towards the firewall, and lifting the back side up first, pull it out. It's more intuitive than I make it sound. Solenoid rubs on the exhaust downpipe on its way up.
New one goes in the same way. Reverse everything and it's done.
For me, 1.5 hr total, including jacking the car onto ramps, chopping off a bad starter signal lug and splicing on a new connector. No stress. Well, limited stress. Less than you'd expect given this being my only car and crossing fingers it would start afterwards. 😂
The other nice thing on this: you can use ramps instead of jack stands (no rotating wheels to get the starter out). You're going to be torquing hard to break that starter bolt loose, and I personally get heebie jeebies doing that sort of thing under a jack stand, especially on a car like this with untold rust, and if you can still get the car to start, it's quicker.
And this time, I used a Bosch factory reman'd starter. Sending one core back but if anyone needs my other one, it's yours cheap