08. (B) Starting systems.pdf

7/25/2019 08. (B) Starting systems.pdf

1/14

STARTING SYSTEMS

CONTENTS

page page

DESCRIPTION AND OPERATION

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 2

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 3

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1

DIAGNOSIS AND TESTING

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8

STARTER MOTOR NOISE - 2.5L ENGINE . . . . . 7

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 9

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3

REMOVAL AND INSTALLATION

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 10

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . 12

SPECIFICATIONS

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 13

DESCRIPTION AND OPERATION

STARTING SYSTEM

DESCRIPTION

An electrically opera ted engine sta rting system is

s t a n d a r d f a c t or y -i n s t a l l ed e q u ip m en t on t h i s m od e l.

The starting system is designed to provide the vehi-

cle operator with a convenient, efficient a nd reliable

m e a n s o f c r a n k i n g a n d s t a r t i n g t h e i n t e r n a l c o m bu s -

t i o n e n g i n e u s e d t o p o w e r t h e v e h i c l e a n d a l l o f i t s

a c ce ss or y s y s t em s f r om w i t h i n t h e s a f e a n d s ecu r e

confines of the passenger compartment. See the own-

ers manual in the vehicle glove box for more infor-

m a t i on a n d i n st r u ct i on s on t h e r ecom m en d ed u s e

a n d op er a t i o n of t h e f a c t or y -i n s t a l l ed s t a r t i n g s y s -

tem.

The starting system consists of the following com-

ponents:

B a t t e r y

S t a r t e r r e l a y

Starter motor (including an integral starter sole-

noid)

Ignition switch

C l u t c h p e d a l p o s i t i o n s w i t c h (m a n u a l t r a n s m i s -

sion)

P a r k /n e ut r a l p os i t ion s w i t ch (a u t o m a t i c t r a n s -

mission) Wire ha rnesses and connections (including the

battery cables).

This group provides complete service informa tion

f o r t h e s t a r t e r m o t o r a n d t h e s t a r t e r r e l a y . C o m p l e t e

s er v ice i n for m a t i on f or t h e ot h er s t a r t i n g s y st e m

components can be located as fol lows:

Refer to Battery in the proper section of Group8A - Battery for complete service information for the

battery.

Refer to Ignition Switch and Key Lock Cyl-inder i n t h e p r op er s ect i on of Gr o u p 8 D - I g n i t i on

System for complete service information for the igni-

tion switch.

Refer to Clutch Pedal Position Switch i n t h eproper section of Group 6 - Clutch for complete ser-

vice information for the clutch pedal position switch.

Refer to Park/Neutral Position Switch in t h eproper section of G roup 21 - Tra nsmission for com-

plete service information for the park/neutra l posi-

tion switch.

Refer to the proper section of Group 8W - Wir-ing Diagrams for complete service information andc i r c u i t d i a g r a m s f o r t h e s t a r t i n g s y s t e m w i r i n g c o m -

ponents.

Group 8A covers the Battery, Group 8B covers the

St a r t i n g Sy s t e m s , a n d Gr o u p 8C cov er s t h e C h a r g i n g

Sy s t e m . We h a v e s e pa r a t e d t h e se s y s t e m s t o m a k e i te a s ie r t o l oca t e t h e i n for m a t i on y ou a r e s eek in g

w i t h i n t h i s S e r vi ce M a n u a l . H o w e ve r, w h e n a t t e m pt -

i n g t o d i a g n os e a n y of t h e s e s y st e m s , i t i s i m p or t a n t

that you keep their interdependency in mind.

T h e ba t t e r y , s t a r t i n g , a n d c h a r g i n g s y s t e m s i n t h e

vehicle operate with one another, and must be tested

as a complete system. In order for the vehicle to start

a n d ch a r g e p r op er l y, a l l of t h e com p on e n t s t h a t a r e

used in these systems must perform within specifica-

tions.

Th e d i a g n os t i c p r oce d ur e s u s ed i n e a ch of t h e s e

groups include t he m ost basic conventiona l diagnostic

m e t h od s , t o t h e m or e s op h is t i ca t e d O n -B oa r d Di a g -

nostics (OBD) buil t into the Powertrain Control Mod-

u l e (P C M ). U s e of a n i n du ct i on -t y pe m i ll ia m p er e

a mmeter, volt/ohmmeter, bat tery charg er, car bon pile

r h e os t a t (l oa d t e s t er ), a n d 12-v ol t t e s t l a m p m a y be

required.

Al l O B D -s en s ed s y st e ms a r e m on i t or ed b y t h e

P C M . E a c h m o n i t o r e d c i r c u i t i s a s s i g n e d a Di a g n o s -

tic Trouble Code (DTC). The P CM will store a DTC in

electronic memory for any fai lure i t detects. Refer to

On-Board Diagnostic Test For Charging System

TJ STARTING SYSTEMS 8B - 1


2/14

i n t h e Di a g n o si s a n d Te st i n g s ect i on of Gr o u p 8 C -

Charging System for more information.

OPERATION

The starting system components form two separate

circuits. A high-amperage feed circuit tha t feeds the

s t a r t e r m o t o r be t w e e n 1 5 0 a n d 3 5 0 a m p e r e s , a n d al ow -a m p e r a g e con t r o l ci r cu i t t h a t op er a t e s on l es s

t h a n 20 a m p e r es . Th e h i g h -a m p e ra g e f ee d ci r cu i t

com p on e n t s i n cl u d e t h e ba t t e r y, t h e ba t t e r y ca bl e s,

t h e con t a c t d i sc p or t i on of t h e s t a r t e r s ol en oi d , a n d

the sta rter motor. The low-am perage control circuit

com p on e n t s i n cl u d e t h e i g n it i on s w i t ch , t h e cl u t ch

p ed a l p os it i on s w i t ch (m a n u a l t r a n s m is si on ), t h e

p a r k /n e u t r a l p os i t ion s w i t ch (a u t o m a t i c t r a n s m is -

sion), the starter relay, the electromagnetic windings

o f t h e s t a r t e r s o l e n o i d , a n d t h e c o n n e c t i n g w i r e h a r -

ness components.

I f t h e v e h icl e i s e q u ip pe d w i t h a m a n u a l t r a n s m is -

sion, i t has a clutch pedal position switch instal led ins e r i e s be t w e e n t h e i g n i t i o n s w i t c h a n d t h e c o i l ba t -

tery terminal of the starter relay. This normally open

s w i t ch p rev en t s t h e s t a r t er r el a y f r om b ei n g e ne r-

g iz ed w h en t h e i gn it i on s w it ch i s t u rn ed t o t h e

m om e n t a r y St a r t p os i t ion , u n l es s t h e c l u t ch p ed a l i s

depressed. This feature prevents starter motor oper-

a t i on w h il e t h e cl ut ch d is c a n d t h e f ly w h eel a r e

e n ga g e d . Th e s t a r t e r r e la y coi l g r o u n d t e r m in a l i s

a l w a y s g r ou n d ed on v eh i cl es w i t h a m a n u a l t r a n s -

mission.

I f t h e v e h icl e i s e q u i pp ed w i t h a n a u t o m a t i c t r a n s -

mission, battery voltage is supplied through the low-

a m p e r a g e c on t r o l c ir cu i t t o t h e coi l ba t t e r y t e r m in a lof t h e s ta r t er r ela y w h en t h e ig nit ion s w it ch is

t u r n e d t o t h e m o m en t a r y St a r t p os i t ion . Th e p a r k /

neutral position switch is instal led in series between

t h e s t a r t er r el a y coi l g r ou n d t e rm in a l a n d g r ou n d .

This normally open switch prevents the starter relay

f r om b ei n g e ne rg iz ed a n d t h e s t a r t e r m ot or f r om

op er a t i n g u n les s t h e a u t om a t i c t r a n s m is si on g ea r

selector is in the Neutral or Park positions.

W h e n t h e s t a r t e r r e l a y c o i l i s e n e r g i z e d , t h e n o r -

m a l l y op en r e la y con t a ct s cl os e. Th e r e la y con t a c t s

connect the relay common feed terminal to the relay

n or m a l l y op en t e r m in a l . Th e cl os ed r e la y con t a c t s

energize the starter solenoid coil windings.

The energized solenoid pull-in coil pulls in the sole-

n oi d p lu n g er. Th e s ol en oi d p lu n g er p u ll s t h e s h i ft

l e v e r i n t h e s t a r t e r m o t o r . T h i s e n g a g e s t h e s t a r t e r

o v e r r u n n i n g c l u t c h a n d p i n i o n g e a r w i t h t h e s t a r t e r

r i n g g e a r o n t h e m a n u a l t r a n s m i s s i o n f l y w h e e l o r o n

t h e a u t o m a t i c t r a n s m is s ion t o r q u e c on v er t e r d r i ve

plate.

As t h e s ol en oi d p lu n g er r ea c h es t h e e nd of i t s

travel , the solenoid contact disc completes the high-

amperage starter feed circuit and energizes the sole-

noid plunger hold-in coil. Current now flows between

t h e s o l e n o i d ba t t e r y t e r m i n a l a n d t h e s t a r t e r m o t o r ,

energizing the starter.

Once th e engine sta rts, the overrunning clutch pro-

t e c t s t h e s t a r t e r m o t o r f r o m d a m a g e by a l l o w i n g t h e

s t a r t er p in i on g ea r t o s p in f a s t er t h a n t h e p in i on

shaft . When the driver releases the ignition switch tothe On position, the sta rter relay coil is de-energized.

Th i s ca u s es t h e r el a y con t a c t s t o op en . Wh en t h e

r el a y con t a c t s op en , t h e s t a r t e r s ol en oi d p lu n ge r

hold-in coil is de-energized.

When the solenoid plung er hold-in coil is de-ener-

gized, the solenoid plunger return spring returns the

plunger to i ts relaxed position. This causes the con-

tact disc to open the starter feed circuit , and the shift

lever to disengage the overrunning clutch and pinion

g e a r f r o m t h e s t a r t e r r i n g g e a r .

Fo ll ow i n g a r e g e ne r a l d e scr i pt i on s of t h e m a jor

components in the starting system.

STARTER MOTOR

DESCRIPTION

T h e s t a r t e r m o t o r s u s e d f o r bo t h t h e 2 .5 L a n d t h e

4.0L e n gi n es a v a i l a bl e i n t h i s m od e l a r e n o t i n t er -

ch a n g ea b l e. B o t h s t a r t e r m ot or s a r e m ou n t ed w i t h

t w o s cr e w s , bu t t h e 2 .5L s t a r t e r m ot o r i s m o u n t ed t o

t h e r i g h t r e a r cor n e r o f t h e e n g i n e bl ock , w h i l e t h e

4 .0 L s t a r t e r m o t o r i s m o u n t e d t o t h e m a n u a l t r a n s -

m i s si on cl u t ch h ou s in g or a u t o m a t i c t r a n s m i s s ion

t or q u e con v er t er h ou s in g on t h e r i gh t s id e of t h e

engine.

E a ch of t h e s e s t a r t e r m ot o r s i n c or p or a t e s s e v er a lof t h e s a m e f ea t u r e s t o cr e a t e a r e li a bl e, e ff ici en t ,

compact, l ightweight and powerful unit . The electric

motors of both starters have four brushes contacting

the motor commutator. The 2.5L starter motor uses

four permanent magnets for the field poles, while the

4.0L sta rter motor features four electromagnetic field

coils wound around four pole shoes. The 2.5L starter

m ot or i s r a t e d a t 1. 2 k i low a t t s (a b ou t 1. 6 h o r se-

p ow e r ) ou t pu t a t 12 v ol t s, w h i le t h e 4. 0L s t a r t er

m ot or i s r a t e d a t 1. 4 k i low a t t s (a b ou t 1. 9 h o r se-

power) output at 12 volts.

B o t h of t h e se s t a r t e r m o t or s a r e s e r vi ce d o n ly a s a

u n it w i t h t h ei r s t a r ter s ol en oi ds , a n d ca n n ot b e

r e pa i r e d . I f e it h e r com p on e n t i s f a u l t y or d a m a g ed ,

t h e e nt i r e s t a r t e r m ot or a n d s t a r t er s ol en oi d u n it

must be replaced.

OPERATION

Th e se s t a r t e r m o t or s a r e e q u ip pe d w i t h a p la n e -

t a r y g e a r r e d uct i on (i n t e r me d ia t e t r a n s m is s ion ) s y s -

tem. The planetary gear reduction system consists of

a g e a r t h a t i s i n t e g r a l t o t h e o u t p u t e n d o f t h e e l e c -

t r ic m ot or a r ma t u re s ha f t t h a t is in con t in ua l

8B - 2 STARTING SYSTEMS TJ

DESCRIPTION AND OPERATION (Continued)


3/14

e n g a g e m e n t w i t h a l a r g e r g e a r t h a t i s s p l i n e d t o t h e

i n p u t e n d o f t h e s t a r t e r p i n i o n g e a r s h a f t . T h i s f e a -

t u r e m a k e s i t p os s ibl e t o r e d uce t h e d i m en s i on s of

t h e s t a r t e r . A t t h e s a m e t i m e , i t a l l o w s h i g h e r a r m a -

t u r e r ot a t i on a l s pe ed a n d d e li v er s i n cr e a s ed t o r q u e

t h r ou g h t h e s t a r t e r p i ni on g ea r t o t h e s t a r t er r i ng

gear.T h e s t a r t e r m o t o r s f o r bo t h e n g i n e s a r e a c t i v a t e d

b y a n i n t eg r a l h ea v y d u t y s t a r t e r s o le noi d s w i t ch

m ou n t e d t o t h e ov er r u n n i n g cl u t ch h ou s in g . Th i s

electromecha nical switch connects an d disconnects

t h e f e e d o f b a t t e r y v o l t a g e t o t h e s t a r t e r m o t o r a n d

a c t u a t e s a s h i f t f o r k t h a t e n g a g e s a n d d i s e n g a g e s t h e

s t a r t e r p i n i o n g e a r w i t h t h e s t a r t e r r i n g g e a r .

Both starter motors use an overrunning clutch and

s t a r t e r p i n i on g e a r u n i t t o e n g a g e a n d d r i ve a s t a r t e r

r in g g ea r t h a t i s i nt eg r a l t o t h e f ly w h eel (m a n ua l

tra nsmission) or t orque converter drive plate (aut o-

m a t i c t r a n s m i s s i o n ) m o u n t e d o n t h e r e a r c r a n k s h a f t

f l a n g e. Sh i m s a r e a v a i l a ble a n d ca n be u s ed t o a d ju stthe 2.5L sta rter motor mounting position t o correct

f o r i m p r o p e r s t a r t e r p i n i o n g e a r t o s t a r t e r r i n g g e a r

engagement.

STARTER RELAY

DESCRIPTION

Th e s t a r t e r r e la y i s a n e le ct r o m ech a n i c a l d e vi ce

that switches battery current to the pull-in coil of the

starter solenoid when the ignition switch is turned to

t h e S t a r t p os i t ion . Th e s t a r t e r r e l a y i s l oca t e d i n t h e

Power Distribution Center (PDC), in the engine com-

p a r t m e n t . Se e t h e f u s e a n d r e la y l a y o ut l a be l a f f i xe dt o t h e i n si de s u rf a ce of t h e P D C cov er f or s t a r t e r

relay identification and location.

Th e s t a r t er r el a y i s a I n t er n a t ion a l S t a n d a r ds

O r g a n i z a t i on (I SO ) r e l a y. R e la y s con f or m i n g t o t h e

ISO specifications have common physical dimensions,

cu r r en t ca p a c i t ie s, t e r m in a l p a t t e r n s , a n d t e r m in a l

functions.

Th e s t a r t e r r e la y ca n n o t be r e p a i r ed or a d ju st e d

a n d , i f f a u l t y o r d a m a g e d , i t m u s t be r e p l a c e d .

OPERATION

The ISO relay consists of an electromagnetic coil, a

resistor or diode, and three (two fixed and one mov-

able) electrical contacts. The movable (common feed)

relay contact is held against one of the fixed contacts

(normally closed) by spring pressure. When the elec-

t r o ma g n e t i c c oi l i s e n er g i ze d , i t d r a w s t h e m ov a bl e

contact away from the normally closed fixed contact ,

a n d h ol d s i t a g a i n s t t h e ot h e r (n or m a l l y op en ) f i xe d

contact.

Wh e n t h e e le ct r o ma g n e t i c coi l i s d e -e n er g i ze d ,s pr i n g p r e s su r e r e t u r n s t h e m ov a bl e c on t a ct t o t h e

normally closed position. The resistor or diode is con-

nected in parallel with the electromagnetic coil in the

r e l a y , a n d h e l p s t o d i s s i p a t e v o l t a g e s p i k e s t h a t a r e

produced when the coil is de-energized.

DIAGNOSIS AND TESTING

STARTING SYSTEM

DIAGNOSIS

Th e ba t t e r y, s t a r t i n g , a n d ch a r g i n g s y s t em s op er -a t e w i t h o n e a n o t h e r , a n d m u s t b e t e s t e d a s a c o m -

p le t e s y s t em . I n or d er f or t h e v eh i cl e t o s t a r t a n d

ch a r g e p r op er l y, a l l of t h e com p on e n t s i n v ol v ed i n

these systems must perform within specifications.

Group 8A covers the Battery, Group 8B covers the

St a r t i n g Sy s t e m s , a n d Gr o u p 8C cov er s t h e C h a r g i n g

Sy s t e m . We h a v e s e pa r a t e d t h e se s y s t e m s t o m a k e i t

e a s ie r t o l oca t e t h e i n for m a t i on y ou a r e s eek in g

w i t h i n t h i s S e r vi ce M a n u a l . H o w e ve r, w h e n a t t e m pt -

i n g t o d i a g n os e a n y of t h e s e s y st e m s , i t i s i m p or t a n t

that you keep their interdependency in mind.

Th e d i a g n os t i c p r oce d ur e s u s ed i n t h e s e g r ou p s

include the most basic conventional diagnostic meth-ods, to the more sophisticated On-Board Diagnostics

(O B D ) b ui lt i nt o t h e P ow e rt r a in C on t r ol M od ul e

(PCM). Use of an induction-type mill iampere amme-

ter, volt/ohmmeter, ba tt ery charger, ca rbon pile r heo-

s t a t (l oa d t es t er ), a n d 12-v ol t t es t l a m p m a y b e

required.

Al l O B D -s en s ed s y st e ms a r e m on i t or ed b y t h e

P C M . E a c h m o n i t o r e d c i r c u i t i s a s s i g n e d a Di a g n o s -

tic Trouble Code (DTC). The P CM will store a DTC in

electronic memory for any fai lure i t detects. Refer to

On-Board Diagnostic Test For Charging Systemi n t h e Di a g n o si s a n d Te st i n g s ect i on of G r ou p 8 C -

Charging System for more information.


DESCRIPTION AND OPERATION (Continued)


4/14

Starting System Diagnosis

CONDITION POSSIBLE CAUSE CORRECTION

STARTER FAILS TO

OPERATE.

1. Battery discharged or

faulty.2. Starting circuit wiring

faulty.3. Starter relay faulty.4. Ignition switch faulty.

5. Clutch pedal positionswitch faulty.6. Park/Neutral positionswitch faulty or

misadjusted.7. Starter solenoid faulty.8. Starter motor faulty.

1. Refer to Battery in the Diagnosis and Testing section of

Group 8A - Battery. Charge or replace the battery, ifrequired.

2. Refer to Starting System in Group 8W - WiringDiagrams. Test and repair the starter feed and/or controlcircuits, if required.

3. Refer to Starter Relay in the Diagnosis and Testingsection of this group. Replace the starter relay, ifrequired.4. Refer to Ignition Switch and Key Lock Cylinder in the

Diagnosis and Testing section of Group 8D - IgnitionSystem. Replace the ignition switch, if required.5. Refer to Clutch Pedal Position Switch in the Diagnosisand Testing section of Group 6 - Clutch.

6. Refer to Park/Neutral Position Switch in the Diagnosisand Testing section of Group 21 - Transmission. Replace

the park/neutral position switch, if required.7. Refer to Starter Motor in the Diagnosis and Testing

section of this group. Replace the starter motor assembly,if required.8. If all other starting system components and circuits testOK, replace the starter motor assembly.

STARTER ENGAGES,FAILS TO TURNENGINE.

1. Battery discharged orfaulty.2. Starting circuit wiring

faulty.3. Starter motor faulty.4. Engine seized.

1. Refer to Battery in the Diagnosis and Testing section ofGroup 8A - Battery. Charge or replace the battery, ifrequired.

2. Refer to Starting System in Group 8W - WiringDiagrams. Test and repair the starter feed and/or controlcircuits, if required.3. If all other starting system components and circuits test

OK, replace the starter motor assembly.4. Refer to Engine Diagnosis in the Diagnosis and Testingsection of Group 9 - Engine.

STARTER ENGAGES,SPINS OUT BEFOREENGINE STARTS.

1. Starter ring gear faulty.2. Starter motor faulty.

1. Refer to Starter Motor in the Removal and Installationsection of this group. Remove the starter motor to inspectthe starter ring gear. Replace the starter ring gear, ifrequired.

2. If all other starting system components and circuits testOK, replace the starter motor assembly.

STARTER DOES NOTDISENGAGE.

1. Starter motorimproperly installed.2. Starter relay faulty.

3. Ignition switch faulty.4. Starter motor faulty.

1. Refer to Starter Motor in the Removal and Installationsection of this group. Tighten the starter mountinghardware to the correct tightness specifications.

2. Refer to Starter Relay in the Diagnosis and Testingsection of this group. Replace the starter relay, if

required.3. Refer to Ignition Switch and Key Lock Cylinder in theDiagnosis and Testing section of Group 8D - IgnitionSystem. Replace the ignition switch, if required.

4. If all other starting system components and circuits testOK, replace the starter motor assembly.


DIAGNOSIS AND TESTING (Continued)


5/14

INSPECTION

Fo r com p le t e ci r cu i t d i a g r a m s , r e fe r t o StartingSystem i n t h e C o n t e n t s o f Gr o u p 8 W - W i r i n g Di a -g r a m s . B e for e r em ov in g a n y u n it f r om t h e s t a r t i n g

system for repair or diagnosis, perform the following

inspections:

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS OR

SERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.

Battery - Visually inspect the battery for indi-ca t i on s of p hy s ica l d a m a g e a n d l oos e or cor r od ed

cable connections. D etermine t he sta te-of-charge an dcr a n k i n g ca p a c it y of t h e ba t t e r y. C h a r g e or r e pl a c e

t h e b a t t e r y, i f r eq u ir ed . R ef er t o Battery in t heproper section of Group 8A - Battery for complete ser-

vice information for the battery.

Ignition Switch - Visually inspect the ignitions w i t ch f or i n d ica t i on s of p h y si ca l d a m a g e a n d l oos e

or corroded wire harness connections. Refer to Igni-tion Switch and Key Lock Cylinder in the propers ect i on of Gr o u p 8D - I g n i t i on Sy s t e m f or com p le t e

service information for the ignition switch.

Clutch Pedal Position Switch- If the vehiclei s eq u ip ped w i t h a m a n u a l t r a n s m is si on , v is u a ll y

i n s pe ct t h e cl u t ch p ed a l p os i t ion s w i t ch f or i n d ica -t i o n s o f p h y s i c a l d a m a g e a n d l o o s e o r c o r r o d e d w i r e

ha rness connections. Refer to Clutch Pedal Posi-tion Switch in t h e pr oper s ect ion of G r ou p 6 -Clutch for complete service information for the clutch

pedal position switch.

Park/Neutral Position Switch- If the vehiclei s e q u i pp ed w i t h a n a u t o m a t i c t r a n s m i ss i on , v i su a l l y

inspect the park/neutra l position switch for indica-

t i o n s o f p h y s i c a l d a m a g e a n d l o o s e o r c o r r o d e d w i r e

h a r n e s s con n e ct i on s . R e fe r t o Park/Neutral Posi-tion Switch in t h e p rop er s ect i on of G r o up 21 -Tra nsmission for complete service informa tion for th e

par k/neutr a l position sw itch. Starter Relay - Vi s ua l l y i n s pe ct t h e s t a r t e r

relay for indications of physical damage and loose or

corroded wire harness connections.

Starter Motor - Vi s ua l l y i n s pe ct t h e s t a r t e rmotor for indications of physical damage and loose or

corroded wire harness connections.

Starter Solenoid - Visually inspect the startersolenoid for indications of physical damage and loose

or corroded wire harness connections.

Wiring - Visually inspect the wire harnesses ford a m a g e. R epa i r or r epl a ce a n y f a ul t y w i ri ng , a s

required. Refer to the proper section of Group 8W -Wiring Diagrams for complete service informat iona n d c i r c u i t d i a g r a m s f o r t h e s t a r t i n g s y s t e m w i r i n g

components.

TESTING

COLD CRANKING TEST

Fo r com p le t e ci r cu i t d i a g r a m s , r e fe r t o StartingSystem in t h e C o n t en t s of Gr o u p 8 W - Wi r in g Di a -g r a m s . T h e ba t t e r y m u s t be f u l l y - c h a r g e d a n d l o a d -

t e s t ed bef or e p r oce ed i n g . R e fe r t o Battery in t h eDia gnosis a nd Testing section of G roup 8A - B at tery

for the procedures.

(1) C o n ne ct a s u it a bl e v o lt -a m p e r e t e st e r t o t h e

ba t t e r y t e r m in a l s (Fi g . 1). Se e t h e i n s t r u ct i on s p r o-

vided by the manufacturer of the volt-ampere tester

being used.

(2) Fu l ly e n ga g e t h e p a r k in g br a k e .

(3) I f t h e v eh i cl e i s e q ui pp ed w i t h a m a n u a l t r a n s -

mission, place the gearshift selector lever in the Neu-

t r a l p o s i t i o n a n d bl o c k t h e c l u t c h p e d a l i n t h e f u l l y

depressed position. If the vehicle is equipped with an

a u t o m a t i c t r a n s m i s s ion , p la c e t h e g ea r s h i f t s el ect o r

lever in the Park position.

(4) Ver if y t h a t a l l l a mps a n d a cces sor ies a r e

turned off.

(5) To p r ev en t t h e e n gi n e f r om s t a r t i n g , r e m ov e

the Automat ic Shut Down (ASD ) relay. The ASD relayis located in the Power Distribution Center (PDC), in

t h e e n g i n e c o m p a r t m e n t . R e f e r t o t h e f u s e a n d r e l a y

layout label affixed to the underside of the PDC cover

for ASD relay identification and location.

(6) R ot a t e a n d h ol d t h e i g n i t i on s w i t ch i n t h e St a r t

pos it ion . N ot e t h e cr a n ki ng v ol t a ge a n d cu r ren t

(amperage) draw readings shown on the volt-ampere

tester.

(a ) I f t h e v o l t a g e r e a d s be l o w 9 .6 v o l t s , r e f e r t o

Starter Motor i n t h e Di a g n o si s a n d Te st i n g s ec-tion of this group. If the starter motor is OK, refer

Fig. 1 Volts-Amps Tester Connections - Typical




6/14

t o Engine Diagnosis in t he Dia gnosis a nd Testings e c t i o n o f Gr o u p 9 - E n g i n e f o r f u r t h e r t e s t i n g o f

t h e e n g i n e . I f t h e s t a r t e r m o t o r i s n o t O K, r e p l a c e

t h e f a u l t y s t a r t e r m o t o r .

(b) I f t h e v o l t a g e r e a d s a bo v e 9 .6 v o l t s a n d t h e

cu r r en t (a m p e r a g e) d r a w r e a d s bel ow s pe ci fi ca -

tions, refer to Feed Circuit Test in this section.(c) If the voltage reads 12.5 volts or greater andt h e s t a r t e r m o t o r d o e s n o t t u r n , r e f e r t o ControlCircuit Testing in this section.

(d) If the voltage reads 12.5 volts or greater and

t h e s t a r t e r m o t o r t u r n s v e r y s l o w l y , r e f e r t o FeedCircuit Test in this section.

NOTE: A cold engine will increase the starter cur-rent (amperage) draw reading, and reduce the bat-

tery voltage reading.

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method)

will determine i f there is excessive resistance in the

high-amperage feed circuit . For complete circuit dia-

g r a m s , r e f e r t o Starting System i n t h e C o n t e n t s o fGroup 8W - Wiring Diagrams.

Wh en p er f or m in g t h es e t e st s , i t i s i mp or t a n t t o

r e m e m be r t h a t t h e v o l t a g e d r o p i s g i v i n g a n i n d i c a -

t i on of t h e r es is t a n ce b et w e en t h e t w o poi nt s a t

w h i ch t h e v ol t m et e r p r obes a r e a t t a c h ed .

Example: W h e n t e s t i n g t h e r e s i s t a n c e o f t h e ba t -t e r y p o s i t i v e c a bl e , t o u c h t h e v o l t m e t e r l e a d s t o t h e

battery positive cable clamp and the cable connector

a t t h e s t a r t e r s o l e n o i d . I f y o u p r o be t h e ba t t e r y p o s -i t iv e t e r m in a l p os t a n d t h e ca b l e c on n ect or a t t h e

s t a r t e r s o l e n o i d , y o u a r e r e a d i n g t h e c o m bi n e d v o l t -

age drop in the bat tery positive cable clamp-to-termi-

nal post connection and the battery positive cable.

Th e f ol l ow i n g op er a t i on w i l l r e q u ir e a v ol t m et e r

accura te to 1/10 (0.10) volt . B efore performing the

t e st s , b e ce rt a i n t h a t t h e f ol low i n g p roce du r es a r e

accomplished:

Battery is fully-charged and load-tested. Refer to

Battery in t h e D i a g n os is a n d Te st i n g s ect i on ofGroup 8A - Battery for the procedures.

Fu l l y e n g a g e t h e p a r k i n g br a k e .

I f t h e v e h i c l e i s e q u i p p e d w i t h a m a n u a l t r a n s -mission, place the gea rshift selector lever in the Neu-

t r a l p o s i t i o n a n d bl o c k t h e c l u t c h p e d a l i n t h e f u l l y

depressed position. If the vehicle is equipped with an

a u t o m a t i c t r a n s m i s s ion , p la c e t h e g ea r s h i f t s el ect o r

l ev er i n t h e P a r k p os i t ion .

Ve r if y t h a t a l l l a m p s a n d a c ce ss or i es a r e t u r n e d

off.

To prevent the engine from sta rting, remove the

Automatic ShutDown (ASD) relay. The ASD relay is

l oca t e d i n t h e P o w e r Di s t r i bu t i on C e n t er (P D C ), i n

t h e e n g i n e c o m p a r t m e n t . R e f e r t o t h e f u s e a n d r e l a y

layout label affixed to the underside of the PDC cover

for ASD relay identification and location.

(1) C o n n ect t h e p os i t iv e l ea d of t h e v ol t m et e r t o

t h e ba t t e r y n e ga t i v e t e r m in a l p os t . C o n n ect t h e n e g-

a t i v e l ea d of t h e v ol t m et e r t o t h e b a t t e ry n eg a t i ve

ca b l e cl a m p (F i g. 2). R ot a t e a n d h ol d t h e i gn i t ion

switch in the Start position. Observe the voltmeter. Ifvoltage is detected, correct the poor conta ct between

t h e c a bl e c l a m p a n d t h e t e r m i n a l p o s t .

(2) C o n n ect t h e p os i t iv e l ea d of t h e v ol t m et e r t o

the battery positive terminal post . Connect the nega-

tive lead of th e voltmeter to t he ba ttery positive cable

clamp (Fig. 3). Rotate and hold the ignition switch in

t h e St a r t p os i t ion . O bse r ve t h e v ol t m et e r. I f v ol t a g ei s d et e ct e d, cor r ect t h e p oor con t a c t b et w e en t h e

c a bl e c l a m p a n d t h e t e r m i n a l p o s t .

(3) Connect the voltmeter to measure between the

ba t t e r y p os i t iv e t e r m i n a l p o st a n d t h e s t a r t e r s ol e-

n o i d ba t t e r y t e r m i n a l s t u d (Fi g . 4 ) . R o t a t e a n d h o l d

Fig. 2 Test Battery Negative Connection Resistance- Typical

Fig. 3 Test Battery Positive Connection Resistance -Typical




7/14

the ignition switch in the Start position. Observe the

voltmeter. If the reading is above 0.2 volt , clean and

tighten the ba ttery cable connection at the solenoid.

R e pe a t t h e t e st . I f t h e r e a d i n g i s s t i l l a bov e 0.2 v ol t ,

replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

b a t t er y n eg a t iv e t er m in a l pos t a n d a g ood cl ea n

ground on the engine block (Fig. 5). Rotate and hold

the ignition switch in the Start position. Observe the

voltmeter. If the reading is above 0.2 volt , clean and

t i g h t e n t h e ba t t e r y n e g a t i v e c a bl e a t t a c h m e n t o n t h e

e n g i n e bl o c k . R e p e a t t h e t e s t . I f t h e r e a d i n g i s s t i l l

a b ov e 0. 2 v ol t , r ep la c e t h e f a u lt y b a t t e ry n eg a t i ve

cable.

(5) C o n n ect t h e p os i t iv e l e a d of t h e v ol t m et e r t o

t h e s t a r t e r h o u s in g . C o n n ect t h e n e g a t i v e l e a d of t h e

v ol t m et e r t o t h e ba t t e r y n e ga t i v e t e r m in a l p os t (Fi g .

6 ) . R o t a t e a n d h o l d t h e i g n i t i o n s w i t c h i n t h e S t a r t

p os it i on . O bs er v e t h e v ol t m et e r. I f t h e r ea d i n g i s

a b ov e 0. 2 v ol t , cor r ect t h e p oor s t a r t e r t o e ng in e

block ground contact.

I f t h e r e si s t a n ce t e s t s d e t ect n o f e ed ci r cu i t p r ob-

l em s , r e fe r t o Starter Motor i n t h e D i a g n o s i s a n dTesting section of th is group.

CONTROL CIRCUIT TESTING

The sta rter control circuit components should be

t e s t e d i n t h e o r d e r i n w h i c h t h e y a r e l i s t e d , a s f o l -

lows:

Starter Relay - Refer t o Starter Relay in t h eDi a g n o si s a n d Te st i n g s ect i on of t h i s g r ou p f or t h e

procedures.

Starter Solenoid - Refer to Starter Motor int h e Di a g n o si s a n d Te st i n g s ect i on of t h i s g r ou p f or

the procedures.

Ignition Switch - R ef er t o Ignition Switchand Key Lock Cylinder in th e Dia gnosis a nd Test-

ing section of G roup 8D - Ignition Sy stem for th e pro-cedures.

Clutch Pedal Position Switch- If the vehiclei s eq u ipped w i t h a m a n ua l t r a n sm is si on , r ef er t o

Clutch Pedal Position Switch in t h e D i a g n os isan d Testing section of G roup 6 - Clutch for t he pro-

cedures.

Park/Neutral Position Switch- If the vehiclei s e q u i p p e d w i t h a n a u t o m a t i c t r a n s m i s s i o n , r e f e r t o

Park/Neutral Position Switch in t h e D i a g n os isand Testing section of G roup 21 - Tran smission for

the procedures.

Wire harnesses and connections - R e f e r t oStarting System in t h e C on t en t s of G r ou p 8W -Wiring Diagrams for complete circuit diagrams.

STARTER MOTOR NOISE - 2.5L ENGINE

Se e t h e St a r t e r M o t o r No i s e Di a g n o s i s c h a r t (Fi g .

7 ). I f t h e c o m p l a i n t i s s i m i l a r t o C o n d i t i o n s 1 a n d 2

in the chart , correction can be made by placing shims

between the starter motor and the engine block using

the following procedures:

(1 ) I f t h e c o m p l a i n t i s s i m i l a r t o C o n d i t i o n 1 , t h e

s t a r t e r m o t o r m u s t be m o v e d t o w a r d t h e s t a r t e r r i n g

Fig. 4 Test Battery Positive Cable Resistance -Typical

Fig. 5 Test Ground Circuit Resistance - Typical

Fig. 6 Test Starter Ground - Typical




8/14

g e a r by r e m o v i n g s h i m s f r o m bo t h s t a r t e r m o u n t i n g

p a d s on t h e e n gi n e bl ock (Fi g . 8 ). R e fe r t o StarterMotor i n t h e R em ov a l a n d I n s t a l la t i on s ect i on ofthis group for the procedures.

NOTE: The shim thickness is 0.381 mm (0.015 in.).These shims may be stacked if additional thicknessis required.

(2 ) I f t h e c o m p l a i n t i s s i m i l a r t o C o n d i t i o n 2 , t h e

s t a r t e r m o t o r m u s t be m o v e d a w a y f r o m t h e s t a r t e r

r i n g g e a r. Th i s i s d on e by i n s t a l l in g s h i m(s ) a cr os s

b ot h s t a r t e r m ou n t in g p a d s on t h e e ng in e b lock .

M or e t h a n on e s him m a y b e r eq uir ed . R efer t o

Starter Motor i n t h e R e m o v a l a n d I n s t a l l a t i o n s e c -tion of this group for the procedures.

NOTE: This is a condition that will generally causebroken starter (flywheel/torque converter drive

plate) ring gear teeth or broken starter motor hous-ings.

STARTER MOTOR

C o r re ct s t a r t e r m ot o r op er a t i on ca n be con f i rm e d

by performing the following free running bench test .Th i s t e s t ca n on l y b e p e rf or m ed w i t h t h e s t a r t e r

motor removed from the vehicle. Refer to StartingSystem in the Specifications section of this group forthe starter motor specifications.

CAUTION: The 2.5L engine uses a permanent mag-

net starter. Permanent magnet starters are highlysensitive to hammering, shocks, external pressureand reverse polarity. This starter motor must neverbe clamped in a vise by the starter field frame. The

starter should only be clamped by the mountingflange. Do not reverse the battery cable connec-

tions to this starter motor when testing. The perma-nent magnets may be damaged and the starterrendered unserviceable if it is subjected to any of

these conditions.

(1) R em ov e t h e s t a r t e r m ot or f r om t h e v eh i cl e.

R e f e r t o Starter Motor i n t h e R e m o v a l a n d I n s t a l -lation section of this group for the procedures.

(2) M ou n t t h e s t a r t e r m ot or s ecu r el y i n a s of t -

ja w e d ben ch v i se . Th e v is e ja w s s h ou l d be c l a m p ed

o n t h e m o u n t i n g f l a n g e o f t h e s t a r t e r m o t o r . Ne v e r

c l a m p o n t h e s t a r t e r m o t o r by t h e f i e l d f r a m e .

Fig. 7 Starter Motor Noise Diagnosis

Fig. 8 Starter Motor Shim




9/14

(3) C on n e ct a s u it a bl e v ol t -a m p e r e t e s t e r a n d a

12-volt battery to the starter motor in series, and set

t h e a m met er t o t h e 100 a m per e s ca l e. S ee t h e

i n st r u ct i on s p rov id ed b y t h e m a n u f a ct u r er of t h e

volt-ampere tester being used.

(4) Insta l l a jumper w ire from the solenoid t ermi-

n a l t o t h e s ol en oi d b a t t er y t er m in a l . Th e s t a r term ot or s h ou ld op er a t e . I f t h e s t a r t er m ot or f a i ls t o

operate, replace the faulty starter motor assembly.

(5) Ad ju st t h e ca r b on p il e l oa d of t h e t e st e r t o

o bt a i n t h e f r e e r u n n i n g t e s t v o l t a g e . R e f e r t o Start-ing System in t h e S p eci fi ca t i on s s ect i on of t h i sg r ou p f or t h e s t a r t e r m o t or f r ee r u n n i n g t e st v ol t a g e

specifications.

(6) Not e t h e r e a d i n g o n t h e a m m et e r a n d com p a r e

t h is r ea d in g t o t h e f ree r un nin g t es t m a xim um

a m p er a g e d r a w . R e fe r t o Starting System in t h eSp eci f ica t i o n s s ect i on of t h i s g r ou p f or t h e s t a r t e r

m ot or f r ee r u n ni n g t e st m a x im u m a m p er a g e d r a w

specifications.(7 ) I f t h e a m m e t e r r e a d i n g e x c e e d s t h e m a x i m u m

a m per a g e d r a w s peci fi ca t i on , r epl a ce t h e f a ul t y

starter motor assembly.

STARTER SOLENOID

Th i s t e s t ca n on l y be p er f or m e d w i t h t h e s t a r t e r

motor removed from the vehicle.

(1) R em ov e t h e s t a r t e r m ot or f r om t h e v eh i cl e.

Refer to Starter Motor i n t h e R e m o v a l a n d I n s t a l -lation section of this group for the procedures.

(2) Disconnect the wire from the solenoid field coil

terminal .

(3) Check for continuity between the solenoid ter-minal and the solenoid field coil terminal with a con-

tinuity tester (Fig. 9). There should be continuity. If

O K, g o t o St e p 4 . I f n o t O K, r e pl a c e t h e f a u l t y s t a r t e r

motor assembly.

(4) Check for continuity between the solenoid ter-

minal an d the solenoid case (Fig. 10). There should

b e c on t i n ui t y. I f n ot O K , r ep la c e t h e f a u lt y s t a r t e r

motor assembly.

STARTER RELAY

The starter relay (Fig. 11) is located in the Power

Di s t r i bu t i on C e n t er (P D C ), i n t h e e n gi n e c om p a r t -

m e n t . R e fe r t o t h e f u s e a n d r e la y l a y ou t l a be l a f f i xe d

t o t h e u n d e r s i d e o f t h e P D C c o v e r f o r s t a r t e r r e l a y

identification a nd locat ion. For complete circuit dia-

g r a m s , r e f e r t o Starting System i n t h e C o n t e n t s o fGroup 8W - Wiring Diagrams.

(1 ) R e m o v e t h e s t a r t e r r e l a y f r o m t h e P DC . R e f e r

t o Starter Relay in t h e R em ov a l a n d I n s t a l la t i onsection of th is group for t he procedures.

(2) A r e l a y i n t h e d e -e n er g i ze d p os i t ion s h ou l dh a v e c o n t i n u i t y be t w e e n t e r m i n a l s 8 7 A a n d 3 0 , a n d

no continuity between terminals 87 and 30. If OK, go

t o St e p 3 . I f n o t O K, r e p l a c e t h e f a u l t y r e l a y .

(3) Resistance between terminals 85 and 86 (elec-

tromagnet) should be 75 5 oh m s . I f O K, g o t o St e p

4 . I f n o t O K, r e p l a c e t h e f a u l t y r e l a y .

(4) C on n ect a b a t t er y t o t er m in a l s 85 a n d 86.

Th e r e s h o ul d n ow be con t i n u it y bet w e e n t e r m in a l s

30 and 87, and no continuity between terminals 87A

a n d 30. I f O K, p e r for m t h e R e l a y C i r cu i t Te st t h a t

follows. If not OK, replace the faulty relay.

RELAY CIRCUIT TEST

(1) The relay common feed terminal cavity (30) is

con n e ct e d t o ba t t e r y v ol t a g e a n d s h ou l d be h o t a t a l l

t imes. If OK, go to Step 2. If not OK, repair the open

c i r c u i t t o t h e f u s e i n t h e P DC a s r e q u i r e d .

Fig. 9 Continuity Test Between Solenoid Terminaland Field Coil Terminal - Typical

Fig. 10 Continuity Test Between Solenoid Terminaland Solenoid Case - Typical

Fig. 11 Starter Relay




10/14

(2) Th e r e la y n or m a l l y cl os ed t e r m in a l (87A) i s

connected to terminal 30 in the de-energized position,

bu t i s n o t u s e d f o r t h i s a p p l i c a t i o n . Go t o St e p 3 .

(3) The relay normally open terminal (87) is con-

nected to the common feed terminal (30) in the ener-

gized position. This terminal supplies bat tery volta ge

t o t h e s t a r t e r s ol en oi d f ie ld coi ls . Th e r e s h o u ld becon t i n u it y bet w e e n t h e c a v i t y f or r e la y t e r m in a l 87

a n d t h e s t a r t e r s o l e n o i d t e r m i n a l a t a l l t i m e s . I f O K,

go to Step 4. If not OK, repair the open circuit to the

starter solenoid as required.

(4) The coil bat tery terminal (86) is connected to

t h e e l e c t r o m a g n e t i n t h e r e l a y . I t i s e n e r g i z e d w h e n

t h e i g n i t i o n s w i t c h i s h e l d i n t h e St a r t p o s i t i o n . O n

v eh icl es w i t h a m a n ua l t r a n sm is si on , t h e cl ut ch

pedal must be fully depressed for this test . Check for

b a t t e r y v ol t a g e a t t h e c a v it y f or r el a y t e rm in a l 86

w i t h t h e i g n i t i o n s w i t c h i n t h e St a r t p o s i t i o n , a n d n o

v ol t a g e w h en t h e i gn i t ion s w i t ch i s r el ea s e d t o t h e

O n p o s i t i o n . I f O K , g o t o S t e p 5 . I f n o t O K w i t h a na u t o m a t i c t r a n s m i s s ion , ch e ck f or a n op en or s h or t

c i r c u i t t o t h e i g n i t i o n s w i t c h a n d r e p a i r , i f r e q u i r e d .

I f t h e ci r cu it t o t h e i g n it i on s w i t ch i s O K , r ef er t o

Ignition Switch and K ey Lock Cylinder i n t h eDia gnosis an d Testing section of G roup 8D - Ignition

Sy s t e m f o r t e s t i n g o f t h e i g n i t i on s w i t ch . I f n o t O K

w i th a m a nu a l t r a ns mis sion , ch eck t h e cir cu it

b et w een t h e r el a y a n d t h e cl ut ch ped a l pos it i on

s w i t ch f or a n op en or a s h or t . I f t h e c ir cu it i s O K ,

refer to Clutch Pedal Position Switch i n t h e Di a g -nosis a nd Testing section of G roup 6 - Clut ch for test -

i n g o f t h e s w i t c h .

(5) The coil ground terminal (85) is connected tot h e e le ct r o ma g n e t i n t h e r e la y . O n v eh i cl es w i t h a

m a n u a l t r a n s m i s s i o n , i t i s g r o u n d e d a t a l l t i m e s . O n

v eh icles w it h a n a u t om a t ic t r a ns mis sion , it is

g r ou n d ed t h r o ug h t h e p a r k /n e ut r a l p os i t ion s w i t ch

o n l y w h e n t h e g e a r s h i f t s e l e c t o r l e v e r i s i n t h e P a r k

or Neutral positions. Check for continuity to ground

a t t h e c a v i t y f o r r e l a y t e r m i n a l 8 5 . I f n o t O K w i t h a

m a n u a l t r a n s m i s s i o n , r e p a i r t h e c i r c u i t t o g r o u n d a s

r e q u i r e d . I f n o t O K w i t h a n a u t o m a t i c t r a n s m i s s i o n ,

check for a n open or short circuit to t he pa rk/neutra l

position switch and repair, i f required. If the circuit

t o t h e p a r k /n e u t r a l p os i t ion s w i t ch i s O K, r e fe r t o

Park/Neutral Position Switch in t h e D i a g n os isan d Testing section of G roup 21 - Tra nsmission for

testing of th e pa rk/neutra l position switch.

REMOVAL AND INSTALLATION

STARTER MOTOR

REM OVAL

2.5L ENGINE(1) D is con n ect a n d i sol a t e t h e b a t t e r y n eg a t i ve

cable.

(2) Raise and support the vehicle.

(3) Wh i le s u pp or t i n g t h e s t a r t e r m ot o r w i t h on e

h a n d , u s e t h e o t h e r h a n d t o r e m o v e t h e t w o s c r e w s

t h a t s ecu r e t h e s t a r t er m ot or t o t h e e ng in e b lock

(Fig. 12).

(4) Lower the starter motor from the engine block

far enough to access and remove the nut that secures

t h e s ol en oi d w i r e h a r n es s con n ect or ey el et t o t h e

s ol en oi d t e r m in a l s t u d . Al w a y s s u pp or t t h e s t a r t e r

m ot or d u r in g t h i s p roce ss , d o n o t l et t h e s t a r t e r

m o t o r h a n g f r o m t h e w i r e h a r n e s s .

(5 ) R e m o v e t h e n u t t h a t s e c u r e s t h e ba t t e r y c a bl e

harness connector eyelet to the solenoid battery ter-

m i n a l s t u d . A lw a y s s u p p or t t h e s t a r t e r m o t or d u r i ng

t h i s p r o c e s s , d o n o t l e t t h e s t a r t e r m o t o r h a n g f r o m

t h e w i r e h a r n e s s .

(6) R em ov e t h e b a t t e ry ca b l e a n d s ol en oi d w i r e

connector eyelets from the solenoid terminal studs.

(7) R em ov e t h e s t a r t er m ot or a n d a n y s t a r t er

motor shims (i f used) from the engine compartment.

Fig. 12 Starter Motor Remove/Install - 2.5L Engine




11/14

4.0L ENGINE

(1) D is con n ect a n d i sol a t e t h e b a t t e ry n eg a t i ve

cable.

(2) Raise and support the vehicle.

(3) R e m ov e t h e l ow e r (f or w a r d f a c in g ) m ou n t i n g

screw from the starter motor (Fig. 13).

(4) Wh i le s u pp or t i n g t h e s t a r t e r m ot o r w i t h on e

h a n d , u s e t h e o t h e r h a n d t o r e m o v e t h e u p p e r (r e a r

facing) mounting screw from the starter motor.(5 ) L o w e r t h e s t a r t e r m o t o r f r o m t h e f r o n t o f t h e

t r a n s m is si on cl ut ch h ou s in g or t or q u e con v er t er

h ou s in g f a r e nou g h t o a c ce ss a n d r em ov e t h e n u t

t h a t s e c u r e s t h e ba t t e r y c a bl e e y e l e t t o t h e s o l e n o i d

battery terminal (Fig. 14). Always support the starter

m ot or d u ri n g t h i s p roce ss , d o n ot l et t h e s t a r t e r


(6) Remove the battery cable eyelet from the sole-

n oi d b a t t e ry t e rm in a l . Al w a y s s u pp or t t h e s t a r t er



(7) Disconnect the solenoid terminal wire ha rness

con n ect or f r om t h e con n ect or r ece pt a c le on t h e

s t a r t e r s ol en oi d . Al w a y s s u pp or t t h e s t a r t e r m ot o r

during this process, do not let the starter motor hang

f r o m t h e w i r e h a r n e s s .

(8) Remove the sta rter motor from the engine com-

p a r t m e n t .

INSTALLATION

2.5L ENGINE

(1 ) P o s i t i o n t h e s t a r t e r m o t o r i n t h e e n g i n e c o m -

p a r t m e n t .

(2) Instal l the battery cable and solenoid wire con-

nector eyelets onto the solenoid terminal studs.

(3) I n s ta l l a n d t i gh t en t h e n u t t h a t s ecu r es t h e

bat tery cable ha rness connector eyelet to t he solenoid

bat tery t erminal stud . Tighten the nut to 10 Nm (90

i n . l bs .). Al w a y s s u pp or t t h e s t a r t er m ot or d u ri n g



(4) I n s ta l l a n d t i gh t en t h e n u t t h a t s ecu r es t h e

solenoid wire harness connector eyelet to the solenoid

terminal stud. Tighten t he nut to 6 Nm (55 in. lbs.).

Alwa ys support the st ar ter motor during this process,

d o n o t l e t t h e s t a r t e r m o t o r h a n g f r o m t h e w i r e h a r -

ness.

(5) P o si ti on t h e s t a r t er m ot or a n d a n y s t a r t er

m o t o r s h i m s t h a t w e r e r e m o v e d t o t h e e n g i n e bl o c k

and loosely instal l both of the mounting screws.

NOTE: Shim thickness available is 0.381 mm (0.015

in.). Refer to Starter Motor Noise - 2.5L Engine inthe Diagnosis and Testing section of this group formore information.

(6) Ti gh t en b ot h of t h e s t a r t er m ot or m ou n t in g

screws. Tighten the screws to 45 Nm (33 ft . lbs.).

(7) Lower the vehicle.

(8) Reconnect the battery negative cable.

4.0L ENGINE

(1) P o s it i on t h e s t a r t e r m ot o r i n t h e e n gi n e c om -

p a r t m e n t .

(2) Reconnect the solenoid terminal wire har ness

connector to t he connector recepta cle on the sta rter

s ol en oi d . Al w a y s s u pp or t t h e s t a r t e r m ot o r d u r i ng



(3) I n s t a l l t h e ba t t e r y ca bl e e y el et on t o t h e s ol e-

n oi d b a t t e r y t e rm i na l . Al w a y s s up por t t h e s t a r t er

Fig. 13 Starter Motor Remove/Install - 4.0L Engine

Fig. 14 Starter Wire Harness Remove/Install - 4.0LEngine


REMOVAL AND INSTALLATION (Continued)


12/14



(4) I n st a l l a n d t i gh t en t h e n ut t h a t s ecu res t h e

ba t t e r y ca bl e e y e le t t o t h e s o le n oi d ba t t e r y t e r m in a l .

Tighten the nut to 10 Nm (90 in. lbs.). Alwa ys sup-

port the starter motor during this process, do not let

t h e s t a r t e r m o t o r h a n g f r o m t h e w i r e h a r n e s s .(5) P os it i on t h e s t a r t er m ot or t o t h e f r on t of t h e

t r a n s m is si on cl ut ch h ou s in g or t or q u e con v er t er

housing and loosely instal l both the upper and lower

mounting screws.

(6) Ti gh t e n t h e l ow e r (f or w a r d f a ci n g) s t a r t e r

motor mounting screw. Tighten the screw to 41 Nm

(30 ft. lbs.).

(7) Ti gh t e n t h e u pp er (r ea r w a r d f a ci n g) s t a r t e r

motor mounting screw. Tighten the screw to 54 Nm

(40 ft. lbs.).

(8) Lower the vehicle.


STARTER RELAY

REM OVAL

(1) D is con n ect a n d i sol a t e t h e b a t t e ry n eg a t i ve

cable.

(2) Remove the cover from the Power Distribution

Center (PDC) (Fig. 15).

(3) S e e t h e f us e a n d r el a y l a y ou t l a b el a f f ix ed t o

the underside of the PDC cover for starter relay iden-

ti fication and location.

(4 ) R e m o v e t h e s t a r t e r r e l a y f r o m t h e P DC .

INSTALLATION

(1) S e e t h e f us e a n d r el a y l a y ou t l a b el a f f ix ed t othe underside of the PDC cover for the proper starter

relay location.

(2 ) P o s i t i o n t h e s t a r t e r r e l a y i n t h e p r o p e r r e c e p -

t a c l e i n t h e P D C .

(3 ) A l i g n t h e s t a r t e r r e l a y t e r m i n a l s w i t h t h e t e r -

m i n a l ca v i t i es i n t h e P DC r e ce pt a cl e.

(4) P u s h d ow n f i rm l y o n t h e s t a r t e r r e la y u n t i l t h e

t e r m i n a l s a r e f u l l y s e a t e d i n t h e t e r m i n a l c a v i t i e s i n

the PDC receptacle.

(5 ) I n s t a l l t h e c o v e r o n t o t h e P DC .


Fig. 15 Power Distribution Center


REMOVAL AND INSTALLATION (Continued)


13/14

SPECIFICATIONS

STARTING SYSTEM

Starter Motor and Solenoid

Manufacturer MitsubishiEngine Application 2.5L, 4.0L

Power Rating 2.5L - 1.2 Kilowatt (1.6 Horsepower)

4.0L - 1.4 Kilowatt (1.9 Horsepower)

Voltage 12 Volts

Number of Fields 4

Number of Poles 4

Number of Brushes 4

Drive Type Planetary Gear Reduction

Free Running Test Voltage 11.2 Volts

Free Running Test Maximum Amperage Draw 90 Amperes

Free Running Test Minimum Speed 2.5L - 2600 rpm

4.0L - 2500 rpm

Solenoid Closing Maximum Voltage Required 7.8 Volts

*Cranking Amperage Draw Test 2.5L - 130 Amperes

4.0L - 160 Amperes

*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.



14/14

Documents

08. (B) Starting systems.pdf