Here's a general outline, but you absolutely must consult a repair manual specific to your 1991 Chevy S-10 and engine type. A Haynes or Chilton manual is a great investment. These manuals provide detailed diagrams and instructions crucial for success.
General Steps (Adapt to your specific engine):
1. Disconnect the battery: Disconnect the negative (-) battery cable first.
2. Access the starter: This is the most variable step. The starter is usually located on the engine block, near the bellhousing (where the engine connects to the transmission). You might need to:
* Remove parts: This could involve removing the air cleaner assembly, various hoses, brackets, and possibly even the exhaust manifold heat shield. The repair manual will detail what needs to come off.
* Work in tight spaces: Expect limited space and awkward angles. A socket wrench with extensions and possibly a universal joint will be invaluable.
3. Disconnect the starter wiring: There will be at least two large cables connecting to the starter – one positive (+) and one for the solenoid. Carefully disconnect these. Take pictures or make notes on their positions to avoid confusion during reassembly. Some have a small wire connected to the starter as well.
4. Remove the starter mounting bolts: These are typically 2 or 3 bolts holding the starter to the engine block. They can be difficult to reach.
5. Remove the starter: Once the bolts are removed, carefully pull the starter away from the engine block. It might be stuck slightly, so some gentle persuasion may be needed. Be mindful of any sharp edges or components.
6. Install the new starter: Install the new starter, reversing the removal steps. Make sure it sits properly in its mounting location.
7. Reconnect the wiring: Carefully reconnect the large and small wires to the starter, ensuring a good, tight connection.
8. Tighten the mounting bolts: Tighten the mounting bolts to the manufacturer's specifications (found in your repair manual).
9. Reconnect the battery: Reconnect the negative (-) battery cable.
10. Test the starter: Try to start the engine. If it doesn't start, double-check all connections and ensure the battery is fully charged.
Important Considerations:
* Repair Manual: Absolutely essential. Don't attempt this without one.
* Tools: You'll likely need sockets, wrenches (both metric and standard), extensions, a universal joint, possibly a ratchet, and possibly a breaker bar for stubborn bolts.
* Safety: Wear safety glasses and gloves. Be cautious of hot engine parts.
* Torque Specifications: Use a torque wrench to tighten bolts to the proper specifications. Over-tightening can damage components.
* Professional Help: If you're not comfortable working on your vehicle, consider taking it to a qualified mechanic.
Attempting this without proper knowledge and tools can lead to further damage. Refer to your repair manual for the specific details related to your 1991 Chevy S-10's engine and starter.
