Removing starter from 4.2AJP

[antwan]

I've now done this twice. Although there are lots of threads for the 4.5, I thought this may be of help to fellow 4.2 owners. Obviously there are other ways and please make sure the battery is disconnected before starting (note no power to open doors or boot so leave them open.)
Takes around 30 mins:
Remove cover at base of windscreen
Disconnect battery
Disconnect the throttle linkage bar at the rear of the fuel rail (don't use the threads which alter the length)
Unplug the injectors
Unscrew the 4 bolts holding the fuel rail in place
Working 4 at a time, pull the injectors out leaving them attached to the fuel rail
Disconnect the fuel feed and plug the pipe, I used the back of a drill bit (at the same time, use a small tub to catch the drips which come from the fuel rail
Rail is now loose bar one pipe which can remain. Turn the whole assembly upside down and move out of the way down towards the fans
You should be able to see the 8mm allen key bolts which hold the starter on and undo (you may need to move some cables around to do this)
Once undone you can spin the starter around and remove its cables
You should be able to wiggle the starter out through the V of the engine (but it is a squeeze, first time I did this I removed the 100amp fuse and first coil pack but tried without the second time)
I found my cable to be loose on the solenoid so I used a lock nut too when reassembling
Be extremely careful not to drop anything into the bellhousing or through the injector ports (I used tape and bags to cover).
Also gently clean the O-rings and ports before reinserting the injectors. I also give them a wiggle when there back in to help them seat.

Couple of photos if it helps:

[Tafford]

I found it easier to just remove the whole inlet assembly inc airboxes - you don't have to mess about with unplugging the injectors / reseating the injector O rings, removing the throttle linkage etc - the whole lot can just be moved sideways / forward enough to get the starter out. Definitely cover the inlets up though!

[Tanguero]

Agreed, removing the inlet setup complete give you far more room and is a lot quicker and easier than separating the injectors. Also less chance of damaging the injector O rings.

[antwan]

Agreed, it is vital that you take care not to drop anything when doing this job.
I will take a look at this way too for the future but I don't see that simply pulling an injector out will damage the o-ring, maybe reinserting. Very simple operation though.

[Tanguero]

It's putting them back in that tends to knacker the O rings, but its avoidable if you are very careful. Whichever technique works best for you.