Aurora 2001-2003

Starter

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Removal & Installation



3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Lower front air deflector
     
    Torque converter cover
     
    Starter electrical connectors
     
    Starter motor

    Click image to see an enlarged view

    Fig. View of the starter-3.5L engine

     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Starter electrical connectors. Torque the positive battery terminal nut to 89 inch lbs. (10 Nm) and the -S- terminal nut to 30 inch lbs. (3.5 Nm).
     
    Torque converter cover
     
    Lower front air deflector
     
    Negative battery cable
     

  2.  

4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Starter electrical connectors
     
    Starter motor

    Click image to see an enlarged view

    Fig. Exploded view of the starter-4.0L engine

     

  4.  

To install:


WARNING
Before installing the starter, torque the inner solenoid and battery terminal nuts to 70 inch lbs. (8 Nm). If not properly tightened, the starter may fail, due to terminal or cap damage.

  1. Install or connect the following:

    Starter motor. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Starter electrical connectors. Torque the positive battery terminal nut to 89 inch lbs. (10 Nm) and the -S- terminal nut to 35 inch lbs. (4 Nm).
     
    Intake manifold
     
    Negative battery cable
     

  2.  

Solenoid or Relay



The solenoid is integrated into the starter and is not separately serviceable.

Testing & Troubleshooting



The starting, or cranking system consists of the battery, starter motor, ignition switch and related wiring. These components are connected electrically. When the ignition switch is turned to the START position (and the theft protection module recognizes the key code, as equipped) battery voltage is applied to the starter solenoid (through the theft deterrent relay, as equipped) S terminal and the solenoid windings are energized. This causes the plunger to move the shift lever, which engages the pinion with the engine flywheel ring gear. The plunger also closes the solenoid contacts, applying battery voltage to the starter motor, which cranks the engine.

When the engine starts, the pinion will over-run and spin at engine speed (rather than starter motor speed) to help prevent flywheel and starter motor damage. When the ignition switch is released (removing the voltage from the solenoid) the plunger return spring disengages the pinion. In order to prevent excessive over-run, the ignition switch should be released as soon as the engine starts.


WARNING
Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor.

When obtaining a replacement starter motor, make sure you get the correct unit. In nearly every case, the starter motor is considered non-serviceable which means they are not user-serviceable and must be replaced as an assembly.

Starter motors do not require lubrication. In general, starter motors give little trouble. Most no-start or hard cranking complaints can be traced to a low battery, poor connections, defective fusible link, engine oil too thick for the weather conditions and other non-starter related causes.

 
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