08b starting systems
TRANSCRIPT
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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.
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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.
DN STARTING SYSTEMS 8B - 3
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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.
8B - 4 STARTING SYSTEMS DN
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
DN STARTING SYSTEMS 8B - 5
DIAGNOSIS AND T ESTING (Continued)
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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.
(2 ) 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 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
8B - 6 STARTING SYSTEMS DN
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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.
(5 ) 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 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
DN STARTING SYSTEMS 8B - 7
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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
DN STARTING SYSTEMS 8B - 9
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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
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 .
(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
(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 ) 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
the starter motor during this process. Do not let the
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
the starter motor during this process. Do not let the
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 .
(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
transmission torque converter housing.
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
the starter motor during this process. Do not let the
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 .
(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
transmission torque converter housing.
(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
8B - 10 STARTING SYSTEMS DN
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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
transmission 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 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
(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) 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
DN STARTING SYSTEMS 8B - 11
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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.
8B - 12 STARTING SYSTEMS DN