Good morning....Bear with me as I explain...yesterday we attempted to swap out my starter, the old bosh starter had a face plate on it that would not fit the new starter.
My mechanic also noticed that the new starter was smaller in size. Installed the new starter, no start. After trouble shooting battery cables and everything else we decided to test both starters off of the vehicle, both starters worked. The new starter worked better of course.
My question is could it be the size of the starter, or could it be the faceplate. My mechanic noted that maybe it was used as a ground. Also we replaced a green frayed wire with a new thicker one, could that make a difference? I would have to order a bosh replacement, but I can get an aftermarket one today. Should I be concerned with size, (that's what she said)...lol. Thank you to all that respond.

 

What year and model?

 

1996 850 2.4 non turbo