Astro, Safari 1997-2005

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove starter motor mounting bolts.
  6.  
  7. Remove shims, if necessary.
  8.  
  9. Disconnect starter electrical connections, after partially lowering the starter.
  10.  
  11. Remove starter motor.
  12.  

To install:

  1. Connect the starter leads to the starter as follows:
    1. Loosely install the starter enable relay lead (1) to the starter solenoid terminal. Align the terminal retaining tab to the starter solenoid.
    2.  
    3. Loosely install alternator output (BAT) lead (3) and the positive battery cable (2) to the solenoid terminal. Align the positive battery cable terminal retaining tab to the starter solenoid.
    4.  
    5. Tighten the starter enable relay lead nut to 18 inch lbs. (2 Nm) and the positive battery cable nut to 14 ft. lbs. (19 Nm).

      Click image to see an enlarged view

      Fig. Starter motor wiring

    6.  

  2.  
  3. Place starter motor into position.
  4.  
  5. Install starter motor mounting bolts but do not tighten it at this time.
  6.  
  7. Install starter motor shims, if equipped.
  8.  
  9. Install outboard starter motor bolt. Tighten the bolts to 32 ft. lbs. (43 Nm).
  10.  
  11. Connect the negative battery cable.
  12.  

Solenoid or Relay



  1. Remove the starter, then place it on a workbench.
  2.  
  3. Remove the screw and the washer from the motor connector strap terminal.
  4.  
  5. Remove the two solenoid retaining screws.
  6.  
  7. Twist the solenoid housing clockwise to remove the flange key from the keyway in the housing, then remove the housing.
  8.  

To install:

  1. Place the return spring on the plunger and place the solenoid body on the drive housing. Turn it counterclockwise to engage the flange key.
  2.  
  3. Place the two retaining screws in position, then install the screw and washer which secures the strap terminal. Install the unit on the starter.
  4.  

 
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