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, 6, 7 and 8
- Disconnect the negative battery cable.
- Remove the air cleaner assembly.
- On the 5S-FE engine remove the battery if necessary.
- On models equipped with cruise control, disconnect the cruise control actuator from the body bracket.
- Disconnect the starter wiring.
- Remove the nut, then disconnect the starter cable.
- Remove the 2 starter bolts.
- Remove the oxygen sensor wiring harness from the engine wire brackets and starter. Extract the starter from the engine.
- Attach the starter and oxygen sensor wiring and brackets. tighten the two bolts to 29 ft. lbs. (39 Nm).
- Attach the starter cable and tighten the nut. Attach all other starter wiring.
- On cruise control models, install the actuator with the 3 bolts, then connect the wiring.
- If removed, install the battery. Face the arrow mark on the hold-down clamp forward.
- Install the air cleaner.
- Connect the negative battery cable.
- Check that the engine starts.
- Reset any electrical components such as the radio and clock.
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.
- To separate 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.
The starter relay is located in the engine compartment relay box. Disconnect the negative battery cable. Wait at least 90 seconds after the cable is disconnected to hinder airbag deployment. Remove the relay box cover and extract the relay. The relay should simply pull out with a slight hindrance.