See Figure 1
Disconnect the field coil lead from the terminal C. Connect the battery to the solenoid switch as shown. See if the clutch pinion gear movement is outward. If the gear does not move perform the hold-in test.
See Figure 2
Attach the battery to the starter as shown and with the clutch pinion gear out, disconnect the negative lead from terminal C. Check to make sure the pinion gear stays in the outward position. If the clutch gear returns inwards, perform the clutch pinion gear return test.
See Figure 3
Disconnect the negative lead from the solenoid body. Check the clutch pinion gear returns inward. If not perform the no-load test.
See Figure 4
Attach a battery and ammeter to the starter. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check the ammeter shows the correct current. 90 amps or less at 11.5 volts on gasoline engines and 180 amps or less at 11.0 volts on diesel engines. If not replace the starter.
REMOVAL & INSTALLATION
See Figures 5 through 12
- Disconnect the negative battery cable from the battery.
- Raise and safely support the vehicle.
- If equipped with 4WD, remove the front driveshaft.
- Remove the nut and disconnect the starter wire.
- Disconnect the starter connector.
- Remove the bolt holding the starter stay to the upper stiffener plate.
- If equipped with 2WD, remove the starter by removing the nut and three bolts.
- If equipped with 4WD, remove the starter by removing the nut, four bolts, and the center bracket.
If equipped with 4WD, install the starter, the center support bracket, nut, and the four bolts. Tighten the bolts as follows:
Bolt A to 41 ft. lbs. (56 Nm)
If equipped with 2WD, install the starter, nut and three bolts. Tighten the bolts as follows:
Bolt A to 41 ft. lbs. (56 Nm)
- Install the bolt to hold the starter stay to the upper stiffener plate. Tighten the bolt to 43 inch lbs. (5 Nm).
- Install the starter connector.
- Connect the starter wire with the nut. Tighten the nut to 78 inch lbs. (9 Nm).
- If equipped with 4WD, install the front driveshaft.
- Connect the negative battery cable.
The starter solenoid (magnetic switch) is an integral part of the starter assembly.
- Remove the starter from the van. Remove the heat insulator from the starter assembly, if equipped.
- Disconnect the wire lead from the magnetic switch terminal.
- Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
- Toseparate the starter housing from the magnetic switch assembly, remove the two screws and the starter housing with the pinion gear (1.6 kW), idler and clutch assembly.
- If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and place the clutch assembly, idler gear, bearing and pinion gear (1.6 kW) in the starter housing.
- Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
- Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts. Tighten the bolts on the 1.4 kW to 52 inch lbs. (6 Nm) and on the 1.6 kW to 82 inch lbs. (9 Nm).
There is a protrusion or tab on each part; make sure you line them up correctly during assembly.
- Connect the wire to the terminal on the magnetic switch and tighten the nut to 52 inch lbs. (6 Nm). Install the heat insulator, if equipped.
- Reinstall the starter on the vehicle. Check starter system for proper operation.
See Figure 13
The starter relay is located up under the dash on the driver side of the vehicle behind the cruise control actuator. Remove the actuator and extract the relay from the fuse block. Simply pull the relay out of the block