Starter TESTING ,REMOVAL , INSTALLATION ,RELAY REPLACEMENT?

TESTING

See Figures 1 and 2

Use the charts to help locate and diagnose starting system problems. Remember that the starter uses large amounts of current during operation, so use all appropriate precautions during testing.

Fig. Fig. 1: Starter system inspection chart

Fig. Fig. 2: Starter system evaluation procedure chart

REMOVAL & INSTALLATION

See Figure 3 to 6

1. Disconnect the negative battery cable.
2. Raise the front of the vehicle and install jackstands beneath the frame. Firmly apply the parking brake and place blocks in back of the rear wheels.

Fig. Fig. 3: Disconnect all wires connected to the starter, including this ground wire on the starter moutnting bolt stud

3. Tag and disconnect the wiring at the starter.

WARNING

When detaching the hardshell connector at the S-terminal, grasp the plastic shell to pull it off. Do not pull on the wire itself. Ensure to pull the connector straight off to prevent damage to the connector and S-terminal. If any part of the connector is damaged, replace the damaged component.

Fig. Fig. 4: Some starters use a self-threading bolt to hold the starter cable

Fig. Fig. 5: Remove the starter motor (arrow) mounting bolts ...

4. Remove the starter mounting bolts and remove the starter.

Fig. Fig. 6: ... then remove the starter-be careful, the starter motor can be quite heavy

To install:

5. Position the starter motor against the engine and install the mounting bolts. Tighten the mounting bolts to 15-19 ft. lbs. (21-27 Nm).
6. Install the starter solenoid connector by pushing it straight on. Ensure that the connector locks in position with a notable click.

Install the starter cable nut to the starter solenoid B-terminal. Tighten the nut to 80-123 inch lbs. (9-14 Nm).

7. Connect any remaining wiring to the starter motor.
8. Lower the front of the vehicle and remove the wheel blocks.
9. Connect the negative battery cable.

RELAY REPLACEMENT

See Figures 7 through 13

1. Disconnect the negative battery cable from the battery.
2. If necessary, remove the power distribution box cover.

Fig. Fig. 7: Label all of the wires on the starter relay before removing them

Fig. Fig. 8: Also remove any protective caps

Fig. Fig. 9: Remove the push-on connectors by pulling them straight off

3. Disconnect the positive battery cable from the battery terminal.
4. Remove the nut securing the positive battery cable to the relay.

Fig. Fig. 10: Remove the cable securing nuts ...

5. Remove the positive cable and any other wiring under that cable.

Fig. Fig. 11: ... then remove all of the cables from the relay

6. Label and remove the push-on wires from the front of the relay.
7. Remove the nut and disconnect the cable from the starter side of the relay.

Fig. Fig. 12: Remove the relay-to-fender apron attaching screws ...

Fig. Fig. 13: ... then remove the relay from the fender

8. Remove the relay mounting bolts and remove the relay.

To install:

9. Install the relay and mounting bolts. Tighten the mounting bolts until snug.
10. Attach all wiring to the relay.
11. If equipped, install the power distribution box cover.
12. Connect the positive (+) cable to the battery.
13. Connect the negative (-) cable to the battery.