08B Starting Systems

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STARTING SYSTEMS

TABLE OF CONTENT S

page page

DESCRIPTION AND OPERATION

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

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

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

DIAGNOSIS AND TESTING

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

STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 7

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . 8

REMOVAL AND INSTALLATION

STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 9

STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 11

SPECIFICATIONS

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION AND OPERATION

STARTING SYSTEM

DESCRIPTION

An electrically operated engine start ing system is

standa rd factory-installed equipment on this model.

The starting system is designed to provide the vehi-

cle operat or with a convenient, efficient an d reliable

means of cranking and starting the internal combus-

t i on e n gi n e u s ed t o p o we r t h e v eh i cl e a n d a l l o f i t s

a cce s sor y s ys t e m s fr om w it h i n t h e s a fe a n d s e cu r e

confines of th e passenger compart ment. See th e own-

ers manu al in the vehicle glove box for more infor-

m a t ion a n d in s t r u ct ion s on t h e r e com m en d ed u s e

a n d op e r a t ion of t h e fa ct or y -i n st a l le d s t a r t i n g s ys -

tem.

The sta rting 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

Start er motor (including a n integral start er sole-

noid)

Ignition switch

Park/neutral position switch

Wire harn esses and connections (including the

battery cables).

This group provides complete service informat ionfor the starter motor and the starter relay. Complete

s e r vi ce i n for m a t i on for t h e ot h e r s t a r t i n g s ys t e m

components can be located as follows:

Refer to B a t t e r y in the proper section of Group

8A - Battery for complete service information for the

battery.

Refer to I g n i t i o n S w i t c h a n d K e y L o c k C y l -

i n d e r in the proper section of Group 8D - Ignition

System for complete service information for the igni-

tion switch.

Refer to P a r k /N e u t r a l P o s i t i o n S w i t c h i n t h e

proper section of Group 21 - Transmission for com-

plete service informat ion for the park/neutral posi-tion switch.

Refer to the proper section of Group 8W - Wir-

i n g D i a g r a m s for complete service information and

circuit diagrams for the starting system wiring com-

ponents.

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

Starting Systems, and Group 8C covers the Charging

System. We have separated these systems to make i t

e a sie r t o l oca t e t h e in for m a t ion y ou a r e s ee kin g

within this Service Manual. However, when attempt-

ing to diagnose any of these systems, i t is important

that you keep their interdependency in mind.

The battery, starting, and charging systems in thevehicle 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 e r ly, a l l o f 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.

T h e d ia g n os t ic p r oce d u r es u s e d i n e a ch of t h e s e

groups include the most basic conventional diagnostic

methods, to the more sophisticated On-Board Diag-

nostics (OBD) built into the Powertrain Control Mod-

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

ammeter, volt/ohmmeter, battery charger, carbon pile

rheostat ( load tester), and 12-volt test lamp may be

required.

All O BD -s en s ed s ys t em s a r e m on it or e d b y t h e

PCM. Ea ch monitored circuit is assigned a Diagnos-

tic Trouble Code (DTC). The PCM will st ore a DTC in

electronic memory for any failure it detects. Refer to

O n- B o a r d D i a g no s t i c T e s t F o r C ha r g i ng Sy s t e m

in the Diagnosis an d Testing section of Group 8C -

Charging System for more information.

DN STARTING SYSTEMS 8B - 1


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OPERATION

The sta rting system components form two separate

circuits. A high-amperage feed circuit that feeds t he

s t a r t e r m o t o r b e t w e e n 1 5 0 a n d 3 5 0 a m p e r e s , a n d a

low-amperage control circuit that operates on less

t h a n 2 0 a m p e r es . T h e h i gh -a m p e r a ge fe ed ci r cu i t

components include t he battery, the battery cables,the contact disc portion of the start er solenoid, an d

the start er motor. The low-amperage control circuit

com p on e n t s i n cl u d e t h e i gn i t ion s w it ch , t h e p a r k /

neutra l position switch, the starter relay, t he electro-

m a g n e t ic w in d in g s of t h e s t a r t e r s ol en oi d, a n d t h e

connecting wire harness components.

Battery voltage is supplied through the low-amper-

age control circuit to the coil battery terminal of the

s t a r t e r r e la y w h e n t h e i gn i t ion s w it ch i s t u r n e d t o

the momentary Start position. The park/neutral posi-

tion switch is installed in series between the starter

relay coil ground terminal and ground. This normally

open switch prevents starter motor operation unlesst h e a u t o m a t ic t r a n s m i ss ion g ea r s e le ct or i s i n t h e

Neutral or Park positions.

W h en t h e s t a r t e r r e la y coi l i s e n e r gi ze d , t h e n or -

mally open relay conta cts close. The relay contacts

connect the relay common feed terminal to the relay

n or m a l ly op e n t e r m in a l . T h e cl os e d 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 e r. T h e s ol en oi d p lu n g er p u l ls t h e s h ift

l ev er i n t h e s t a r t e r m ot or . T h is e n ga g es 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

ring gear on the automatic transmission torque con-

verter or torque converter drive plate.

As t h e s ole n oid p lu n g er r e a ch e s t h e e n d of it s

travel, th e 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 b a 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 start s, the overrunning clutch pro-

tects the starter motor from damage by allowing the

s t a r t er p in ion g ea r t o s p in fa s t er t h a n t h e p in ion

shaft. When t he driver releases th e ignition switch to

the On position, the starter relay coil is de-energized.

T h is ca u s es t h e r e la y con t a ct s t o op en . Wh e n t h e

r e la y con t a c t s op e n , t h e s t a r t e r s ol en oi d p lu n g er

hold-in coil is de-energized.

When the solenoid plunger 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 t he st arter feed circuit , an d t he sh ift

lever to disengage t he overrun ning clutch and pinion

gear from the starter ring gear.

F ol low in g a r e g en e r a l d e scr i pt i on s of t h e m a j or

components in the starting system.

STARTER MOTOR

DESCRIPTION

T h e s t a r t e r m ot or s u s e d f or t h e 4 .7 L e n g in e s a r e

not interchangeable with the starter motors used for

t h e ot h e r a va ila b le e n gin e s for t h is m od el. T h e

s t a r t e r m ot or s u s e d for a l l 5 .2L a n d 5 .9 L e n g in e savailable in this model are interchangeable.

The 4.7L engine starter motor is mounted with two

s cr e ws t o t h e a u t om a t ic t r a n s m is s ion t or q u e con -

v er t e r h ou s in g on t h e l eft s id e of t h e e n gi n e. T h e

s t a r t e r m ot or s for a l l o f t h e r e m a in i n g e n g in e s a r e

m ou n t ed w it h on e s cr ew, a s tu d a n d a n u t t o t h e

aut omatic tra nsmission torque converter housing and

are also located on the left side of the engine.

Each of these start er motors incorporat es several

of t h e s a m e fe a t u r e s t o cr e a t e a r e li a bl e, e ffi ci en t ,

compact, l ightweight and powerful unit . The electric

motors of both starters have four brushes contacting

the motor commutator. These starter motors use fourelectromagnetic field coils wound around four pole

s h o e s . T h e s t a r t e r m o t o r s a r e r a t e d a t 1 .4 k i l o w a t t s

(about 1.9 horsepower) output at 12 volts.

T h e se s t a r t e r m ot or s a r e s e r vi ce d o n ly a s a u n i t

with their starter solenoids, and cannot be repaired.

If either component is faulty or damaged, the entire

s t ar t er m ot or a n d s ta r t er s ole noid u n it m u st b e

replaced.

OPERATION

T h es e s t a r t er m ot or s a r e e qu ip pe d w it h a g ea r

r e d u ct i on (i n t er m e d ia t e t r a n s m i s si on ) s ys t e m . T h e

gear reduction system consists of a gear that is inte-

gral to the output end of the electric motor armature

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

g ea r t h a t is s plin e d t o t h e in p u t e n d o f t h e s t a r t e r

pinion gear shaft . This featu re m akes i t possible to

r e du ce t h e d im e n sion s of t h e s t a r t er . At t h e s a m e

time, i t allows higher armature rotational speed and

delivers increased torque through the starter pinion

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

The starter motors for all engines are activated by

a n in t egr a l h ea vy d u ty s t ar t er s ole noid s wit ch

m ou n t e d t o t h e ove r r u n n in g clu t ch h ou s in g. T h is

electromechanical switch connects and disconnectst 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

actuates a shift fork that engages and disengages the

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 .

T h e se s t a r t e r m ot or s u s e a n ov er r u n n i n g cl u t ch

a n d s t a r t er p in ion g ea r u n it t o e n ga ge a n d d r ive a

s t a r t e r r i n g g e a r t h a t i s i n t e g r a l t o t h e t o r q u e c o n -

verter or torque converter drive plate mounted on the

rear crankshaft f lange.

8B - 2 STARTING SYSTEMS DN

DESCRIPTION AND OPERATION (Continued)


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STARTER RELAY

DESCRIPTION

T h e s t a r t e r r e la y i s a n e le ct r om e ch a n i ca l d e vi ce

tha t switches battery curr ent to th e pull-in coil of the

starter solenoid when the ignition switch is turned to

the Start position. The starter relay is located in thePower Distribution Center (PDC), in the engine com-

partment. See the fuse and relay layout label affixed

t o t h e i n s id e s u r fa ce of t h e P D C cov er for s t a r t e r

relay identification and location.

T he s t ar t er r ela y is a I n te rn a t ion a l S t an d ar ds

Organization (ISO) micro-relay. Relays conforming to

th e ISO specifications ha ve common physical d imen-

sions, current capacities, terminal patterns, and ter-

m in a l fu n ct ion s . T h e I S O m icr o-r e la y t e r mi na l

functions are the same as a conventional ISO relay.

However, th e ISO micro-relay term inal pa ttern (or

footprint) is different, the current capacity is lower,

a n d t h e p h y s i c a l d i m e n s i o n s a r e s m a l l e r t h a n t h o s eof the conventional ISO relay.

T h e s t a r t e r r e la y ca n n o t b e r e p a i r ed or a d ju s t e d

and, if faulty or damaged, i t must be replaced.

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-

tromagnetic coil is energized, i t draws the movable

contact away from the normally closed fixed contact,

and holds i t against the other (normally open) fixed

contact.

W h en t h e e le ct r om a g n et i c coi l i s d e-e n er g iz ed ,

s p r in g p r e ss u r e r e t u r n s t h e m ov a bl e c on t a c t t o t h e

normally closed position. The resistor or diode is con-

nected in parallel with the electromagnetic coil in the

relay, and helps to dissipate voltage spikes that are

produced when the coil is de-energized.

DIAGNOSIS AND TESTING

STARTING SYSTEM

DIAGNOSIS

T h e b a t t e r y, s t a r t i n g, a n d ch a r g in g s ys t e m s op e r-

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 e r for t h e v eh i cl e t o s t a r t a n d

char ge properly, all of the components involved in

these systems must perform within specifications.

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

Starting Systems, and Group 8C covers the Charging

System. We have separated these systems to make i t

e a sie r t o l oca t e t h e in for m a t ion y ou a r e s ee kin g

within this Service Manual. However, when attempt-ing to diagnose any of these systems, i t is important

that you keep their interdependency in mind.

T h e d ia g n os t ic p r oce d u r es u s e d 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 BD ) b u ilt in t o t h e P ow er t r a in C on t r ol M od u le

(PCM). Use of an induction-type milliampere amme-

ter, volt/ohmmeter, battery charger, carbon pile rheo-

s t a t (l oa d t e st e r ), a n d 1 2-volt t e st la m p m a y b e

required.

All O BD -s en s ed s ys t em s a r e m on it or e d b y t h e

PCM. Ea ch monitored circuit is assigned a Diagnos-

tic Trouble Code (DTC). The PCM will st ore a DTC inelectronic memory for any failure it detects. Refer to

O n- B o a r d D i a g no s t i c T e s t F o r C ha r g i ng Sy s t e m

in the Diagnosis an d Testing section of Group 8C -

Charging System for more information.


DESCRIPTION AND OPERATION (Continued)


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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. Park/Neutral positionswitch faulty ormisadjusted.6. Starter solenoid faulty.

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

the park/neutral position switch, if required.6. Refer to Starter Motor in the Diagnosis and Testing

section of this group. Replace the starter motor assembly,if required.

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

STARTER ENGAGES,

FAILS TO TURNENGINE.

1. Battery discharged or

faulty.2. Starting circuit wiringfaulty.3. Starter motor faulty.

4. Engine seized.

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 control

circuits, if required.3. If all other starting system components and circuits testOK, replace the starter motor assembly.4. Refer to Engine Diagnosis in the Diagnosis and Testing

section of Group 9 - Engine.

STARTER ENGAGES,SPINS OUT BEFORE

ENGINE 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 inspect

the 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 mounting

hardware 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 the

Diagnosis 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 T ESTING (Continued)


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INSPECTION

For complete circuit diagrams, refer to St a r t i ng

S y s t e m in the Contents of Group 8W - Wiring Dia-

g r a m s . B e for e r e m ov in g a n y u n i t fr 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.

B a t t e r y - Visually inspect the battery for indi-

ca t i on s of p h ys ica l d a m a g e a n d l oos e or cor r od e d

cable connections. Determine the state-of-charge andcrank ing capacity of the battery. Charge or replace

t h e b a t t er y, i f r e qu ir e d. R efe r t o B a t t e r y in t h e

proper section of Group 8A - Battery for complete ser-

vice information for the battery.

I g n i ti o n S w i t c h - Visually inspect the ignition

switch for indications of physical damage and loose

or corroded wire har ness conn ections. Refer t o I g ni -

t i o n S w i t c h a n d K e y L o c k C y l i n d e r in the proper

section of Group 8D - Ignition System for complete

service information for the ignition switch.

P a r k /N e u t ra l P o s i ti o n S w i t c h - Visually

inspect the park/neutral position switch for indica-

tions of ph ysical damage and loose or corroded wirehar ness connections. Refer to P a r k /N e u t r a l P o s i -

t i on S w i t c h i n t h e p r op er s ect ion of G r ou p 2 1 -

Transm ission for complete service informa tion for th e

park/neutral position switch.

S t a r te r R e l a y - Vi su a l ly i n sp e ct t h e s t a r t e r

relay for indications of physical damage and loose or

corroded wire harness connections.

S t a r te r Mo t o r - Vi su a l ly i n sp e ct t h e s t a r t e r

motor for indications of physical damage and loose or

corroded wire harness connections.

S t a r te r S o l e n o i d - Visually inspect the start er

solenoid for indications of physical damage and loose

or corroded wire harness connections. Wiring - Visually inspect the wire harnesses for

d a m a ge . R ep a ir or r e pl a ce a n y fa u lt y w ir in g , a s

required. Refer to the proper section of G r o up 8 W -

Wi r i ng D i a g r a m s for complete service information

a n d ci r cu i t d ia g r a m s for t h e s t a r t i n g s y s t em w ir i n g

components.

TESTING

COLD CRANKING TEST

For complete circuit diagrams, refer to St a r t i ng

S y s t e m in the Contents of Group 8W - Wiring Dia-

grams. The battery must be fully-charged and load-

tested before proceeding. Refer to B a t t e r y in t h eDiagnosis a nd Testing section of Group 8A - Batt ery

for the procedures.

(1 ) C on n e ct a s u it a b le v ol t -a m p e r e t e s t er t o t h e

battery terminals (Fig. 1). See the instructions pro-

vided by the manufacturer of the volt-ampere tester

being used.

(2) Fully engage the parking brake.

(3 ) P la ce t h e a u t om a t ic t r a n s m is si on g ea r s h ift

selector lever in the Park position.

(4) Ve rify t h a t a ll la m ps a n d a cce ss or ie s a r e

turned off.

(5 ) To p r e ve n t t h e e n gi n e fr om s t a r t i n g, r e m ov e

the Automatic ShutDown (ASD) relay. The ASD relay

is located in the Power Distribution Center (PDC), in

the engine compartment. Refer to the fuse and relay

layout label affixed to the underside of the PDC cover

for ASD relay identification and location.

(6) Rotate and hold th e ignition switch in the Startp os it ion . N ot e t h e cr a n k in g volt a ge a n d cu r r e n t

(amperage) draw readings shown on the volt-ampere

tester.

(a) If the voltage reads below 9.6 volts, refer to

St a r t e r Mo t o r in the Diagnosis and Testing sec-

tion of this group. If the starter motor is OK, refer

t o E n g i n e D i a g n o s i s in the Diagnosis and Testing

section of Group 9 - Engine for furth er testing of

the engine. If the starter motor is not OK, replace

the faulty starter motor.

Fig. 1 Volts-Amps Tester Connections - Typical1 POSITIVE CLAMP

2 NEGATIVE CLAMP

3 INDUCTION AMMETER CLAMP




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

cu r r e n t (a m p e r a ge ) d r a w r e a d s b el ow s p eci fi ca -

tions, refer to F e e d C i r c ui t T e s t in this section.

(c) 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 d o e s n o t t u r n , r e f e r t o C o nt r o l

Circuit Testing in this section.

(d) If the voltage reads 12.5 volts or greater andthe starter motor turns very slowly, refer to F e e d

Circuit 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 if there is excessive resistance in the

high-amperage feed circuit. For complete circuit dia-

grams, refer to S t a r t i n g S y s t e m i n t h e C o n t e n t s o f

Group 8W - Wiring Diagrams.

Wh e n p er for m in g t h e se t e st s , it is im p or t a n t t o

remember that the voltage drop is giving an indica-

t ion of t h e r e si st a n ce b et w ee n t h e t w o p oin t s a t

which the voltmeter probes are attached.

E x a m pl e : 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 b a t -

tery positive cable, touch the voltmeter leads to the

battery positive cable clamp and the cable connector

at the starter solenoid. If you probe the battery pos-

i t iv e t e r m i n a l p os t a n d t h e ca b le con n e ct or a t t h e

start er solenoid, you a re reading th e combined volt-

age drop in the battery positive cable clamp-to-termi-

nal post connection and the battery positive cable.The following operation will require a voltmeter

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

t e s t s, b e ce r t a in t h a t t h e fol low in g p r oce d u r es a r e

accomplished:

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

B a t t e r y in t h e D ia gn os is a n d Te st in g s ect ion of

Group 8A - Battery for the procedures.

Fully engage the parking brake.

Place the automatic transmission gearshift selec-

tor lever in the Park position.

Verify that all lamps and accessories are turned

off.

To prevent the engine from starting, remove theAutomatic Shu tDown (ASD) relay. The ASD relay is

located in the Power Distribution Center (PDC), in

the engine compartment. Refer to the fuse and relay

layout label affixed to the underside of the PDC cover

for ASD relay identification and location.

(1 ) C on n e ct t h e p os it i ve l ea d of t h e v ol t m et e r t o

the battery negative terminal post. Connect the neg-

a t i ve l ea d of t h e v ol t m et e r t o t h e b a t t e r y n e g a t iv e

ca b le 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. If

voltage is detected, correct the poor conta ct between

the cable clamp and the terminal post.


the battery positive terminal post. Connect the nega-

tive lead of the voltmeter to the battery positive cable

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

the Start position. Observe the voltmeter. If voltage

i s d e t ect e d , cor r e ct t h e p oor con t a c t b et w e en t h e

cable clamp and the terminal post.

(3) Connect the voltmeter to measure between the

b a t t e r y p os it i ve t e r m in a l p os t a n d t h e s t a r t e r s ol e-

noid battery terminal stud (Fig. 4). Rotate and hold

the ignition switch in the Start position. Observe the

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

Fig. 2 Test Battery Negative Connection Resistance

- Typical1 VOLTMETER2 BATTERY

Fig. 3 Test Battery Positive Connection Resistance -Typical

1 VOLTMETER

2 BATTERY




7/12

t ighten the battery cable connection at the solenoid.

Repeat the test . If the reading is st i l l above 0.2 volt ,

replace the faulty battery positive cable.

(4) Connect the voltmeter to measure between the

b a t t er y n e ga t ive t e r m in a l p os t a n d a g ood cle a 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

tighten the battery negative cable attachment on the

e n gi n e b l ock . R ep e a t t h e t e s t . I f t h e r e a d in g i s s t i ll

a b ov e 0 .2 v ol t , r e p la ce t h e fa u l t y b a t t e r y n e ga t i vecable.


the starter housing. Connect the negative lead of the

voltmeter to the battery negative terminal post (Fig.

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 e a d in g i s

a b ov e 0 .2 v ol t , c or r e ct t h e p oor s t a r t e r t o e n gi n e

block ground contact.

If the resistance t ests detect no feed circuit prob-

lems, refer to St a r t e r Mo t o r i n t h e D ia g n os is a n d

Testing section of this group.

CONTROL CIRCUIT TESTING

The start er control circuit components should be

t e s t ed i n t h e or d e r i n w h ich t h e y a r e l is t e d, a s fol -lows:

St a r t e r R e l a y - Refer to St a r t e r R e l a y i n t h e

Diagnosis a nd Testing section of th is group for the

procedures.

S t a r te r S o l e n o i d - Refer to St a r t e r Mo t o r in

the Diagnosis a nd Testing section of th is group for

the procedures.

I g n i ti o n S w i t c h - R e fe r t o I g n i ti o n S w i t c h

a n d K e y L o c k C y l i n d e r in the Diagnosis and Test-

ing section of Group 8D - Ignition System for the pro-

cedures.

P a r k /N e u t ra l P o s i ti o n S w i t c h - R efe r t o

P a r k /N e u t ra l P o s i ti o n S w i t c h i n t h e D ia g n os isand Testing section of Group 21 - Transmission for

the procedures.

W i r e h a r n e s s e s a n d c o n n e c t i o n s - Refer to

S t a r ti n g S y s t e m in t h e C on t en t s of G rou p 8 W -

Wiring Diagrams for complete circuit diagrams.

STARTER MOTOR

Correct st arter motor operation can be confirmed

by performing the following free run ning bench test .

T h is t e st ca n on ly b e p er for m e d w it h t h e s t a r t er

motor removed from the vehicle. Refer to St a r t i ng

Fig. 4 Test Battery Positive Cable Resistance -

Typical1 BATTERY

2 VOLTMETER

3 STARTER MOTOR

Fig. 5 Test Ground Circuit Resistance - Typical1 VOLTMETER

2 BATTERY

3 ENGINE GROUND

Fig. 6 Test Starter Ground - Typical1 STARTER MOTOR

2 BATTERY

3 VOLTMETER




8/12


9/12

RELAY CIRCUIT TEST

(1) The relay common feed terminal cavity (30) isconnected to battery voltage and should be hot at all

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

ci r cu i t t o t h e fu s e i n t h e P D C a s r e q u ir e d .

(2 ) T h e r e la y n or m a l ly cl os ed t e r m in a l (8 7A) i s

connected to terminal 30 in the de-energized position,

but is not used for this application. Go to Step 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 battery voltage

t o t h e s t a r t e r s ol en oi d fi el d coi ls . T h e r e s h ou l d b e

continuity between the cavity for relay terminal 87

and the starter solenoid terminal at all t imes. If OK,

go to Step 4. If not OK, repair the open circuit to thestarter solenoid as required.

(4) The coil batt ery terminal (86) is connected to

the electromagnet in the relay. I t is energized when

t h e ign it ion s wit ch i s h e ld in t h e S t a r t p os it ion .

Check for battery voltage at the cavity for relay ter-

m i n a l 8 6 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 S t a r t p o s i -

t ion , a n d n o volt a ge w h en t h e ig n it ion s wit ch is

r e l e a 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

not OK, check for an open or short circuit to the igni-

t i on s w it ch a n d r e p a ir , i f r e q u ir e d . I f t h e ci r cu i t t o

the ignition switch is OK, refer to I g n i t i o n S w i t c h

a n d K e y L o c k C y l i n d e r in the Diagnosis and Test-

ing section of Group 8D - Ignition System for testingof the ignition switch.

(5) The coil ground terminal (85) is connected to

t h e e le ct r om a gn et in t h e r ela y. I t is gr ou n de d

through the park/neutral position switch only when

the gearshift selector lever is in the Park or Neutral

positions. Check for continuity to ground at the cav-

i t y f or r e la y t e r m in a l 8 5. I f n o t O K , c h eck for a n

op e n or s h or t ci r cu i t t o t h e p a r k /n e u t r a l p os it i on

s w it ch a n d r e p a ir , i f r e q u ir e d . I f t h e ci r cu i t t o t h e

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

N e u t ra l P o s i ti o n S w i t c h in t h e D ia gn os is a n d

Testing section of Group 21 - Tran smission for testing

of t he park/neutral position switch.

REMOVAL AND INSTALLATION

STARTER MOTOR

REMOVAL

ALL 5.2L AND 5.9L ENGINE

(1 ) D is con n e ct a n d i sol a t e t h e b a t t e r y n e ga t i ve

cable.

(2) Raise and support the vehicle.

(3) Re move t h e n u t a n d t h e lock w as h er t h a t

s ecu r e s t h e low er m ou n t in g fla n ge of t h e s t a r t er

m ot or t o t h e s t u d on t h e a u t om a t ic t r a n s m is sion

torque converter housing (Fig. 10).

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

h a n d , u s e t h e ot h e r h a n d t o r e m ove t h e s cr e w a n d

w a sh e r t h a t s ecu r e s t h e u p pe r m ou n t in g fla n ge of

t h e s t ar t er m ot or t o t h e a u t om a t ic t r a n sm is sion

torque converter housing.

(5 ) S l id e t h e a u t o m a t ic t r a n s m i s si on cool er t u b e

b r a ck et for w a r d on t h e t u b es fa r e n ou g h for t h e

s t a r t e r m ot or m ou n t i n g fl a n ge t o b e r e m ov ed fr om

the lower mounting stud.

(6 ) L o we r t h e s t a r t e r m ot or fr om t h e fr on t of t h e

automatic transmission torque converter housing far

TERMINAL LEGEND

NUMBER IDENTIFICATION

30 COMMON FEED

85 COIL GROUND

86 COIL BATTERY

87 NORMALLY OPEN

87A NORMALLY CLOSED

Fig. 9 Starter Relay

Fig. 10 Starter Motor Remove/Install - All 5.2L and5.9L Engine

1 EYELET TERMINAL

2 NUT

3 BRACKET

4 STUD

5 STARTER MOTOR

6 LOCK WASHER

7 WIRE HARNESS CONNECTOR

8 NUT

9 SCREW AND WASHER




10/12

e n ou gh t o a cce ss a n d r e m ove t h e n u t t h a t s ecu r e s

t h e b a t t er y p os it ive ca b le e ye le t t e r min a l t o t h e

start er solenoid B(+) terminal stud. Always support

the starter motor during this process. Do not let the

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 .

(7) Remove the battery positive cable eyelet termi-

n a l fr om t h e s ol en oi d B (+ ) t e r m i n a l s t u d . A lw a yssupport the starter motor during this process. Do not

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 .

(8) Disconnect the battery positive cable solenoid

terminal wire harn ess connector from the connector

receptacle on the starter solenoid. Always support


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 .

(9 ) R e m ov e t h e s t a r t e r m ot or fr om t h e a u t o m a t ic

transmission torque converter housing.

4.7L ENGINE


cable.(2) Raise and support the vehicle.

(3 ) R e m ov e t h e s cr e w a n d w a s h er (r e a r w a r d fa c-

i n g) t h a t s e cu r e s t h e l ow er m ou n t i n g fl a n ge of t h e

s t a r t e r m ot or t o t h e a u t o m a t ic t r a n s m is s ion t or q u e

converter housing (Fig. 11).

(4 ) W h il e s u p p or t i n g t h e s t a r t e r m ot or w it 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 s c r e w a n d

w a sh e r (r e a rw a r d fa cin g) t h a t s ecu r e s t h e u p p er

m ou n t in g fla n ge of t h e s t a r t er m ot or t o t h e a u t o-

matic t ransm ission torque converter housing.

(5 ) L o we r t h e s t a r t e r m ot or fr om t h e fr on t of t h e

automatic transmission torque converter housing far

e n ou gh t o a cce ss a n d r e m ove t h e n u t t h a t s ecu r e s

t h e b a t t er y p os it iv e ca b le e ye le t t e r mi n al t o t h e

starter solenoid B(+) terminal stud. Always support


s t a r t e r m ot or h a n g fr om t h e w ir e h a r n e s s .

(6) Remove th e bat tery positive cable eyelet ter mi-

n a l fr om t h e s ol en oi d B (+ ) t e r m i n a l s t u d . A lw a ys

support the starter motor during this process. Do notl 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 .

(7) Disconnect the battery positive cable solenoid

terminal wire harn ess connector from the connector

receptacle on the start er solenoid. Always support



(8 ) R e m ov e t h e s t a r t e r m ot or fr om t h e a u t o m a t ic


INSTALLATION

ALL 5.2L AND 5.9L ENGINE

(1 ) P os it ion t h e s t a r t er m ot or t o t h e a u t om a t ictransmission torque converter housing.

(2) Reconnect the battery positive cable solenoid

t e r m in a l w ir e h a r n e s s con n e ct or t o t h e con n e ct or

receptacle on the start er solenoid. Always support



(3) Install the battery positive cable eyelet termi-

nal onto the solenoid B(+) terminal stud. Always 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 .

(4 ) In s t a ll a n d t igh t e n t h e n u t t h a t s ecu r e s t h e

battery positive cable eyelet terminal to th e sta rter

solenoid B(+) terminal stud. Tighten the nut to 13.6Nm (120 in. lbs.) . Always support the starter motor

d u r in g t h is p r oce ss . D o n o t le t t h e s t a r t er m ot or

h a n g fr om t h e w ir e h a r n e s s .

(5 ) P os it i on t h e h ol e i n t h e s t a r t e r m ot or l ow er

m ou n t in g fla n ge ov er t h e s t u d on t h e a u t om a t ic


(6 ) S l id e t h e a u t o m a t ic t r a n s m i s si on cool er t u b e

bracket rearward on the tubes and into position over

the starter motor upper mounting flange.

(7) Loosely install the screw and washer unit that

s ecu r e s t h e s t a r t e r m ot or u p p er m ou n t i n g f la n g e t o

the aut omatic tr ansmission torque converter housing.

(8 ) L oos e ly i n st a l l t h e l ock w a s h er a n d n u t t h a t

s ecu r e s t h e s t a r t e r m ot or l ow er m ou n t i n g fl a n ge t o

t h e s t u d o n t h e a u t o m a t i c t r a n s m i s s i o n t o r q u e c o n -

verter housing.

(9 ) T ig h t en t h e s cr e w a n d w a s h e r u n i t a n d t h e n u t

t h a t s e cu r e t h e s t a r t e r m ot or m ou n t i n g f la n g e t o t h e

a u t o m a t ic t r a n s m i s si on t or q u e con v er t e r h ou s in g .

Tigh t e n t h e s cr e w a n d t h e n u t t o 6 7 .8 N m (5 0 f t .

lbs.).

(10) Lower the vehicle.

(11) Reconnect th e bat tery n egative cable.

Fig. 11 Starter Motor Remove/Install - 4.7L Engine1 EYELET TERMINAL

2 NUT

3 SCREW AND WASHER (2)

4 STARTER MOTOR

5 WIRE HARNESS CONNECTOR


REMOVAL AND INSTALLATION (Continued)


11/12

4.7L ENGINE

(1 ) P os it ion t h e s t a r t er m ot or t o t h e a u t om a t ic


(2) Reconnect the battery positive cable solenoid

t e r m in a l w ir e h a r n e s s con n e ct or t o t h e con n e ct or

receptacle on the starter solenoid. Always support

the starter motor during this process. Do not let thes 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 .

(3) In stall t he battery positive cable eyelet termi-

nal onto the solenoid B(+) terminal stud. Always 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 .

(4 ) In s t a ll a n d t ig h te n t h e n u t t h a t s ecu r e s t h e

b a t t e r y p o si t iv e ca b le e ye le t t e r m in a l t o t h e s t a r t e r

solenoid B(+) terminal stud. Tighten the nut to 13.6

Nm (120 in. lbs.) . Always support the starter motor

d u r in g t h is p r oce ss . D o n o t le t t h e s t a r t er m ot or

h a n g fr om t h e w ir e h a r n e s s .

(5) P osition the starter motor mounting flange on

the automatic transmission torque converter housingand loosely install the two screw and washer units to

secure i t .

(6 ) T ig h t en t h e t w o s cr e w a n d w a s h er u n i t s t h a t

secure the starter motor mounting flange to the auto-

matic transmission torque converter housing. Tighten

the screws to 67.8 Nm (50 ft. lbs.).

(7) Lower th e vehicle.

(8) Reconnect the battery negative cable.

STARTER RELAY

REMOVAL


cable.

(2) Remove the cover from the Power Distribution

Center (PDC) (Fig. 12).

(3 ) S e e t h e fu s e a n d r e la y l a you t l a be l a f fi xe d t o

the underside of the PDC cover for starter relay iden-

tificat ion an d locat ion.

(4) Remove the starter relay from the PDC.

INSTALLATION

(1 ) S e e t h e fu s e a n d r e la y l a you t l a be l a f fi xe d t o

the underside of the PDC cover for the proper st arter

relay location.

(2 ) P os it i on t h e s t a r t e r r e la y i n t h e p r op e r r e ce p -

t a c le 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 -

minal cavities in the PDC receptacle.

(4) Push down firmly on the starter relay until the

terminals are fully seated in the terminal cavities in

the PDC receptacle.

(5) Install the cover onto the PDC.

(6) Reconnect t he ba tter y negative cable.

Fig. 12 Power Distribution Center1 CLIP

2 BATTERY

3 TRAY

4 NEGATIVE CABLE

5 POSITIVE CABLE

6 CLIP7 FENDER INNER SHIELD

8 POWER DISTRIBUTION CENTER


REMOVAL AND INSTALLATION (Continued)


12/12

SPECIFICATIONS

STARTING SYSTEM

Starter Motor and Solenoid

Manufacturer Denso DensoPart Number 56027702AC 56028715

Engine Application 5.2L, 5.9L 4.7L

Power Rating1.4 Kilowatt

(1.9 Horsepower1.4 Kilowatt

(1.9 Horsepower

Voltage 12 Volts 12 Volts

Pinion Teeth 10 10

Number of Fields 4 4

Number of Poles 4 4

Number of Brushes 4 4

Drive Type Reduction Gear Train Reduction Gear TrainFree Running Test Voltage 11 Volts 11 Volts

Free Running Test Maximum Amperage Draw 73 Amperes 73 Amperes

Free Running Test Minimum Speed 3601 rpm 3601 rpm

Solenoid Closing Maximum Voltage Required 7.5 Volts 7.5 Volts

*Cranking Amperage Draw Test 125 - 250 Amperes 125 - 250 Amperes

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


Documents

08B Starting Systems