Suzuki Aerio, Verona 2002-06

Starter

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Removal & Installation



  1. Remove or disconnect the following:

    Negative battery cable
     
    Starter electrical connections
     
    2 starter mounting bolts
     
    Starter motor
     

  2.  

To install:

  1. Install or connect the following:

    Starter
     
    2 starter mounting bolts and tighten to 96 inch lbs. (10 Nm)
     
    Starter electrical connections
     
    Negative battery cable
     

  2.  

5-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative lead.
  4.  
  5. Remove the air intake between the front cover plate and the air cleaner housing
  6.  
  7. Remove the hose between the charge air cooler and the electronic throttle module.
  8.  
  9. Disconnect the connector and the positive battery lead from the starter motor.
  10.  
  11. Remove the 2 M10 bolts securing the starter motor to the transaxle.
  12.  
  13. Remove the starter motor.
  14.  
  15. Installation is the reverse of removal.

    Click image to see an enlarged view

    Fig. Starter mounting

  16.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative lead.
  4.  
  5. Remove:

    The intake pipe between the front cover plate and the air cleaner
     
    The connector from the mass air flow sensor
     
    The turbocharger control valve from the air cleaner housing
     
    The brake vacuum hose from the air cleaner
     
    The hose clamp between the fresh air intakes
     
    Mass air flow sensor
     
    The air cleaner by pulling it straight up.
     
    The hose clamp on the charge air pipe on the throttle body. Pull the pipe off the throttle body
     
    M8 bolt for the bracket in the cylinder block
     
    M8 nuts in the bracket for the wiring and the engine coolant hose
     
    The blade terminal connector on the solenoid
     
    The nut for the positive lead
     
    The M10 bolts for the mounting for the starter motor
     
    The starter motor.
     

  6.  

To install:

  1. Install:

    The starter motor
     
    The M10 bolts in the transaxle cover
     
    M8 bolt for the support bracket on the engine block. Tighten. The M6 nuts for the bracket on the starter motor
     
    The bracket for the wiring. Use 2 M8 nuts.
     
    The battery positive lead
     
    The blade terminal connector on the solenoid
     
    The charge air pipe on the throttle body
     
    The air cleaner
     
    The fresh air intake
     
    The turbocharger control valve
     
    The brake vacuum hose
     
    The mass air flow sensor connector.
     

  2.  

8-Cylinder Engines
  1. Remove:
    1. The 4 bolts at the suspension turrets
    2.  
    3. The bolts of the upper engine mount on the engine
    4.  
    5. The upper cross stay.
    6.  
    7. The battery negative cable.
    8.  
    9. The expansion tank cap.
    10.  

  2.  
  3. Raise the vehicle.
  4.  
  5. Remove the protective plate (skid plate).
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  6.  
  7. Draining coolant
  8.  
  9. Open the cock on the lower left edge of the radiator.
  10.  
  11. Drain the coolant into a clean receptacle.
  12.  
  13. Close the cock.
  14.  
  15. Installing the protective plate.
  16.  
  17. Install the protective plate.
  18.  
  19. Lower the vehicle.
  20.  
  21. Remove the air cleaner cover by pulling it straight up.
  22.  
  23. Remove:
    1. The 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness.
    2.  
    3. The connector from the mass air flow sensor.
    4.  

  24.  
  25. Remove:
    1. The 2 bolts of the fresh air hose in the front plate.
    2.  
    3. The fresh air hose.
    4.  
    5. The hose clips of the intake manifold between the mass air flow sensor and the electronic throttle module (ETM).
    6.  
    7. The air cleaner by pulling it straight up.
    8.  

  26.  
  27. Remove:
    1. The connector to the brake vacuum valve.
    2.  
    3. The vacuum hose from the vacuum pump by pressing in the quick-action lock.
    4.  
    5. The vacuum hose from the brake vacuum valve.
    6.  
    7. The vacuum hose from the intake manifold.
    8.  
    9. The brake vacuum from the retainer.
    10.  

  28.  
  29. Detach the radiator hoses at the quick-release coupling toward the firewall.
  30.  
  31. Detach the coolant hose from the throttle body by undoing the clamp.
  32.  
  33. Bend aside the coolant hoses.
  34.  
  35. Remove:
    1. The connector to the electronic throttle module (ETM) and the electrical distribution center.
    2.  
    3. The protective cap from the starter motor solenoid.
    4.  
    5. The nut of the positive leads on the starter motor solenoid.
    6.  
    7. The positive leads.
    8.  
    9. The control current lead from the starter motor solenoid.
    10.  

  36.  
  37. Remove:
    1. The 4 bolts.
    2.  
    3. The upper engine mount.
    4.  

  38.  
  39. Remove:
    1. The EVAP valve from the bracket.
    2.  
    3. The line from the EVAP valve to the tank by releasing the quick-action lock.
    4.  
    5. The hose from the intake manifold to the EVAP valve by releasing the hose clip.
    6.  
    7. The 2 bolts of the EVAP valve bracket.
    8.  
    9. The EVAP valve bracket.
    10.  

  40.  
  41. Remove the 3 bolts of the lifting eye and the lifting eye.
  42.  
  43. Open the hose clip and move it to the side.
  44.  
  45. Remove the 2 bolts and the connection pipe. Discard the gasket.
  46.  
  47. Remove the 2 bolts and the starter motor.
  48.  

To install:

Click image to see an enlarged view

Fig. Starter mounting-V8 engine

  1. Install the starter motor. Tighten the 2 bolts.
  2.  
  3. Install a new gasket and the connection pipe on the coolant hose.
  4.  
  5. Install the 2 bolts.
  6.  
  7. Install the clamp on the coolant hose.
  8.  
  9. Fit the clamp in its original position.
  10.  
  11. Install the lifting eye.
  12.  
  13. Install the EVAP valve bracket.
  14.  
  15. Install the hose from the intake manifold to the EVAP valve; secure with the clamp.
  16.  
  17. Install the line to the tank on the EVAP valve; secure with the quick-action lock.
  18.  
  19. Install the EVAP valve on the bracket.
  20.  
  21. Install the upper engine mount.
  22.  
  23. Install the connector to the electronic throttle module (ETM) and the electrical distribution center.
  24.  
  25. Install the positive leads, x 2, on the solenoid.
  26.  
  27. Install the nut.
  28.  
  29. Install the protective cover on the nut.
  30.  
  31. Install the control current lead on the solenoid.
  32.  
  33. Install the 2 coolant hoses on the connections at the firewall; secure with the quick-action lock.
  34.  
  35. Install the coolant hose on the throttle body; secure with the clamp.
  36.  
  37. Install the air cleaner on the left frame member.
  38.  
  39. Install the intake hose on the throttle body; secure with the clamp.
  40.  
  41. Install the connector to the mass air flow sensor.
  42.  
  43. Install the vacuum hose to the vacuum pump; secure with the quick-action lock.
  44.  
  45. Install the vacuum hose on the brake vacuum valve.
  46.  
  47. Install the vacuum hose on the intake manifold; secure with the clamp.
  48.  
  49. Install the brake vacuum valve in the retainer.
  50.  
  51. Install the connector to the brake vacuum valve.
  52.  
  53. Install the fresh air intake manifold.
  54.  
  55. Install the engine control module (ECM) connectors.
  56.  
  57. Install the cross stay between the suspension turrets.
  58.  
  59. Install the 4 bolts in the suspension turrets.
  60.  
  61. Install the bolt of the cross stay mount on the upper engine mount.
    NOTE
    Make sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.

  62.  
  63. Fill with coolant.
  64.  
  65. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluid as necessary.
  66.  

Testing & Troubleshooting



The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch (A/T only), connection wires and the battery cables. When the ignition key is turned to the start position, current flows and energizes the starter motor solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear. The contacts close and the starter motor cranks the engine. In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage. Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held in place. If damaged, replace the starter drive.

Click image to see an enlarged view

Fig. Starter motor with starting circuit components

If the starter is not turning over the engine, check that the wire connections are fastened securely to the starter solenoid and that battery voltage (12 volts) is supplied to the starter.

The starter should have power supplied to it at all times. With the ignition in the START position, power is supplied from the ignition switch terminal to activate the solenoid. The starter motor plunger closes and provides a closed circuit between the battery and the starter motor. The starter motor is grounded to the cylinder block. With both power and ground supplied, a functioning starter motor operates correctly and starts the vehicle.

Possible symptoms due to starting system trouble would be as follows:



Starting motor does not run (or runs slowly)
 
Starting motor runs but fails to crank engine
 
Abnormal noise is heard
 

Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness, (including starting motor switch), starting motor or engine. Do not remove motor just because starting motor does not run. Check following items and narrow down scope of possible causes.



Condition of trouble
 
Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
 
Discharge of battery
 
Mounting of starting motor
 

 
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