DN STARTING SYSTEMS 8B - 1

STARTING SYSTEMS
CONTENTS

page page

GENERAL INFORMATION CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . . 5

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . 4
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
DESCRIPTION AND OPERATION STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 7
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS
DIAGNOSIS AND TESTING STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 8
COLD CRANKING TEST . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION • Park/neutral position switch

• Wire harness and connections.
OVERVIEW This group covers diagnosis of the complete start-
The battery, starting, and charging systems oper- ing system, except the battery. However, this group
ate with one another, and must be tested as a com- only covers service procedures for the starter and
plete system. In order for the vehicle to start and starter relay. Service procedures for other starting
charge properly, all of the components involved in system components can be located as follows:
these systems must perform within specifications. • Battery - refer to Group 8A - Battery for the
Group 8A covers the battery, Group 8B covers the diagnostic and service procedures
starting system, and Group 8C covers the charging • Ignition switch - refer to Group 8D - Ignition
system. Refer to Group 8W - Wiring Diagrams for Systems for the service procedures
complete circuit descriptions and diagrams. We have • Park/neutral position switch - refer to Group 21
separated these systems to make it easier to locate - Transmission for the service procedures
the information you are seeking within this Service • Wire harness and connections - refer to Group
Manual. However, when attempting to diagnose any 8W - Wiring Diagrams for the service procedures.
of these systems, it is important that you keep their
interdependency in mind. STARTING SYSTEM
The diagnostic procedures used in these groups The starting system components form two separate
include the most basic conventional diagnostic meth- circuits. A high-amperage feed circuit that feeds the
ods, to the more sophisticated On-Board Diagnostics starter between 150 and 350 amperes, and a low-am-
(OBD) built into the Powertrain Control Module perage control circuit that operates on less than 20
(PCM). Use of a induction milliampere ammeter, volt/ amperes.
ohmmeter, battery charger, carbon pile rheostat (load Battery voltage is supplied through the low-amper-
tester), and 12-volt test lamp may be required. age control circuit to the coil battery terminal of the
All OBD-sensed systems are monitored by the starter relay when the ignition switch is turned to
PCM. Each monitored circuit is assigned a Diagnos- the Start position. The park/neutral position switch
tic Trouble Code (DTC). The PCM will store a DTC in is installed in series between the starter relay coil
electronic memory for any failure it detects. Refer to ground terminal and ground. This normally open
On-Board Diagnostics Test in Group 8C - Charging switch prevents the starter relay from being ener-
System for more information. gized unless the automatic transmission gear selector
in the Neutral or Park positions.
INTRODUCTION When the starter relay coil is energized, the nor-
The starting system consists of: mally open relay contacts close. The relay contacts
• Battery connect the relay common feed terminal to the relay
• Starter relay normally open terminal. The closed relay contacts
• Starter with an integral solenoid energize the starter solenoid coil windings.
• Ignition switch
8B - 2 STARTING SYSTEMS DN
GENERAL INFORMATION (Continued)
The energized solenoid pull-in coil pulls in the sole- starter solenoid when the ignition switch is turned to
noid plunger. The solenoid plunger pulls the shift the Start position. See Starter Relay in the Diagnosis
lever in the starter. This engages the starter overrun- and Testing section of this group for more informa-
ning clutch and pinion gear with the starter ring tion.
gear on the automatic transmission torque converter. The starter relay is located in the Power Distribu-
As the solenoid plunger reaches the end of its tion Center (PDC), in the engine compartment. Refer
travel, the solenoid contact disc completes the high- to the PDC label for relay identification and location.
amperage starter feed circuit and energizes the sole- The starter relay cannot be repaired and, if faulty
noid plunger hold-in coil. Current now flows between or damaged, it must be replaced.
the solenoid battery terminal and the starter motor,
energizing the starter.
Once the engine starts, the overrunning clutch pro- DIAGNOSIS AND TESTING
tects the starter from damage by allowing the starter
pinion gear to spin faster than the pinion shaft. STARTING SYSTEM
When the driver releases the ignition switch to the For circuit descriptions and diagrams, refer to
On position, the starter relay coil is de-energized. 8W-21 - Starting System in Group 8W - Wiring Dia-
This causes the relay contacts to open. When the grams.
relay contacts open, the starter solenoid plunger
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
hold-in coil is de-energized.
REFER TO GROUP 8M - PASSIVE RESTRAINT SYS-
When the solenoid plunger hold-in coil is de-ener-
TEMS BEFORE ATTEMPTING ANY STEERING WHEEL,
gized, the solenoid plunger return spring returns the
STEERING COLUMN, OR INSTRUMENT PANEL COM-
plunger to its relaxed position. This causes the con-
PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE
tact disc to open the starter feed circuit, and the shift
THE PROPER PRECAUTIONS COULD RESULT IN
lever to disengage the overrunning clutch and pinion
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE
gear from the starter ring gear.
PERSONAL INJURY.

DESCRIPTION AND OPERATION

INSPECTION
Before removing any unit from the starting system
STARTER
for repair or diagnosis, perform the following inspec-
The starter motor incorporates several features to
tions:
create a reliable, efficient, compact, and lightweight
• Battery - Visually inspect the battery for indi-
unit. A planetary gear system (intermediate trans-
cations of physical damage and loose or corroded
mission) is used between the electric motor and the
cable connections. Determine the state-of-charge and
pinion gear. This feature makes it possible to reduce
cranking capacity of the battery. Charge or replace
the dimensions of the starter. At the same time, it
the battery, if required. Refer to Group 8A - Battery
allows higher armature rotational speed and delivers
for more information.
increased torque through the pinion gear to the
• Ignition Switch - Visually inspect the ignition
starter ring gear on the automatic transmission
switch for indications of physical damage and loose
torque converter.
or corroded wire harness connections.
The starter motors for all engines are activated by
• Park/Neutral Position Switch - Visually
a solenoid mounted to the overrunning clutch hous-
inspect the park/neutral position switch for indica-
ing. However, the starter motor and solenoid are ser-
tions of physical damage and loose or corroded wire
viced only as a complete assembly. If either
harness connections.
component is faulty or damaged, the entire starter
• Starter Relay - Visually inspect the starter
assembly must be replaced.
relay for indications of physical damage and loose or
corroded wire harness connections.
STARTER RELAY
• Starter - Visually inspect the starter for indica-
The starter relay is a International Standards
tions of physical damage and loose or corroded wire
Organization (ISO) micro-relay. The terminal desig-
harness connections.
nations and functions are the same as a conventional
• Starter Solenoid - Visually inspect the starter
ISO relay. However, the micro-relay terminal orienta-
solenoid for indications of physical damage and loose
tion (or footprint) is different, the current capacity is
or corroded wire harness connections.
lower, and the relay case dimensions are smaller
• Wiring - Visually inspect the wire harness for
than those of the conventional ISO relay.
damage. Repair or replace any faulty wiring, as
The starter relay is a electromechanical device that
required.
switches battery current to the pull-in coil of the
DN STARTING SYSTEMS 8B - 3
DIAGNOSIS AND TESTING (Continued)

Starting System Diagnosis

CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO 1. Battery discharged or 1. Refer to Group 8A - Battery. Charge or replace the
ENGAGE. faulty. battery, if required.
2. Starting circuit wiring 2. See Cold Cranking Test in the Diagnosis and Testing
faulty. section of this group. Test and repair the starter feed
3. Starter relay faulty. and/or control circuits, if required.
4. Ignition switch faulty. 3. See Relay Test in the Diagnosis and Testing section of
5. Park/Neutral position this group. Replace the starter relay, if required.
switch faulty or 4. See Ignition Switch Test in the Diagnosis and Testing
misadjusted. section of this group. Replace the ignition switch, if
6. Starter solenoid faulty. required.
7. Starter assembly 5. See Park/Neutral Position Switch Test in the Diagnosis
faulty. and Testing section of this group. Replace the park/
neutral position switch, if required.
6. See Solenoid Test in the Diagnosis and Testing section
of this group. Replace the starter assembly, if required.
7. If all other starting system components and circuits test
OK, replace the starter assembly.
STARTER ENGAGES, 1. Battery discharged or 1. Refer to Group 8A - Battery. Charge or replace the
FAILS TO TURN faulty. battery, if required.
ENGINE. 2. Starting circuit wiring 2. See Cold Cranking Test in the Diagnosis and Testing
faulty. section of this group. Test and repair the starter feed
3. Starter assembly and/or control circuits, if required.
faulty. 3. If all other starting system components and circuits test
4. Engine seized. OK, replace the starter assembly.
4. Refer to Group 9 - Engine for the diagnostic and
service procedures.
STARTER ENGAGES, 1. Broken teeth on 1. See Starter in the Removal and Installation section of
SPINS OUT BEFORE starter ring gear. this group. Remove the starter to inspect the starter ring
ENGINE STARTS. 2. Starter assembly gear. Replace the starter ring gear, if required.
faulty. 2. If all other starting system components and circuits test
OK, replace the starter assembly.
STARTER DOES NOT 1. Starter improperly 1. See Starter in the Removal and Installation section of
DISENGAGE. installed. this group. Tighten the starter mounting hardware to the
2. Starter relay faulty. correct torque specifications.
3. Ignition switch faulty. 2. See Relay Test in the Diagnosis and Testing section of
4. Starter assembly this group. Replace the starter relay, if required.
faulty. 3. See Ignition Switch Test in the Diagnosis and Testing
section of this group. Replace the ignition switch, if
required.
4. If all other starting system components and circuits test
OK, replace the starter assembly.

COLD CRANKING TEST (3) Place the automatic transmission gearshift

For circuit descriptions and diagrams, refer to selector lever in the Park position.
8W-21 - Starting System in Group 8W - Wiring Dia- (4) Verify that all lamps and accessories are
grams. The battery must be fully-charged and load- turned off.
tested before proceeding. Refer to Group 8A - Battery (5) To prevent the engine from starting, unplug
for more information. the Automatic ShutDown (ASD) relay. The ASD relay
(1) Connect a suitable volt-ampere tester to the is located in the Power Distribution Center (PDC).
battery terminals (Fig. 1). Refer to the operating Refer to the PDC label for ASD relay identification
instructions provided with the tester being used. and location.
(2) Fully engage the parking brake.
8B - 4 STARTING SYSTEMS DN
DIAGNOSIS AND TESTING (Continued)
age drop in the battery positive cable clamp-to-termi-
nal post connection and the battery positive cable.
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing the
tests, be certain that the following procedures are
accomplished:
• Battery is fully-charged and load-tested. Refer to
Group 8A - Battery for more information.
• Fully engage the parking brake.
• Place the automatic transmission gearshift selec-
tor lever in the Park position.
• Verify that all lamps and accessories are turned
off.
• To prevent the engine from starting, unplug the
Automatic ShutDown (ASD) relay. The ASD relay is
Fig. 1 Volts-Amps Tester Connections - Typical located in the Power Distribution Center (PDC).
(6) Rotate and hold the ignition switch in the Start Refer to the PDC label for ASD relay identification
position. Note the cranking voltage and current and location.
(amperage) draw. (1) Connect the positive lead of the voltmeter to
(a) If the voltage reads below 9.6 volts, remove the battery negative terminal post. Connect the neg-
the starter for bench testing. If the starter bench ative lead of the voltmeter to the battery negative
test is OK, refer to Group 9 - Engine for further cable clamp (Fig. 2). Rotate and hold the ignition
diagnosis of the engine. If the starter bench test is switch in the Start position. Observe the voltmeter. If
not OK, replace the faulty starter. voltage is detected, correct the poor contact between
(b) If the voltage reads above 9.6 volts and the the cable clamp and the terminal post.
current (amperage) draw reads below specifica-
tions, see Feed Circuit Test in the Diagnosis and
Testing section of this group.
(c) If the voltage reads 12.5 volts or greater and
the starter does not turn, see Control Circuit Test
in the Diagnosis and Testing section of this group.
(d) If the voltage reads 12.5 volts or greater and
the starter turns very slowly, see Feed Circuit Test
in the Diagnosis and Testing section of this group.

NOTE: A cold engine will increase the starter cur-

rent (amperage) draw reading, and reduce the bat-
tery voltage reading.

FEED CIRCUIT TEST

The starter feed circuit test (voltage drop method)
will determine if there is excessive resistance in the
Fig. 2 Test Battery Negative Connection Resistance
high-amperage circuit. For circuit descriptions and
- Typical
diagrams, refer to 8W-21 - Starting System in Group (2) Connect the positive lead of the voltmeter to
8W - Wiring Diagrams. the battery positive terminal post. Connect the nega-
When performing these tests, it is important to tive lead of the voltmeter to the battery positive cable
remember that the voltage drop is giving an indica- clamp (Fig. 3). Rotate and hold the ignition switch in
tion of the resistance between the two points at the Start position. Observe the voltmeter. If voltage
which the voltmeter probes are attached. is detected, correct the poor contact between the
Example: When testing the resistance of the bat- cable clamp and the terminal post.
tery positive cable, touch the voltmeter leads to the (3) Connect the voltmeter to measure between the
battery positive cable clamp and the cable connector battery positive terminal post and the starter sole-
at the starter solenoid. If you probe the battery pos- noid battery terminal stud (Fig. 4). Rotate and hold
itive terminal post and the cable connector at the the ignition switch in the Start position. Observe the
starter solenoid, you are reading the combined volt- voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery cable connection at the solenoid.
DN STARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)

Fig. 5 Test Ground Circuit Resistance - Typical

Fig. 3 Test Battery Positive Connection Resistance -
Typical
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.

Fig. 6 Test Starter Ground - Typical

Solenoid Test in the Diagnosis and Testing section of
this group.

Fig. 4 Test Battery Positive Cable Resistance - CONTROL CIRCUIT TEST

Typical For circuit descriptions and diagrams, refer to
(4) Connect the voltmeter to measure between the 8W-21 - Starting System in Group 8W - Wiring Dia-
battery negative terminal post and a good clean grams. The starter control circuit consists of:
ground on the engine block (Fig. 5). Rotate and hold • Battery
the ignition switch in the Start position. Observe the • Starter relay
voltmeter. If the reading is above 0.2 volt, clean and • Starter solenoid
tighten the battery negative cable attachment on the • Ignition switch
engine block. Repeat the test. If the reading is still • Park/neutral position switch
above 0.2 volt, replace the faulty battery negative • Wire harness and connections.
cable. Test procedures for these components should be
(5) Connect the positive lead of the voltmeter to performed in the order in which they are listed, as
the starter housing. Connect the negative lead of the follows:
voltmeter to the battery negative terminal post (Fig.
SOLENOID TEST
6). Rotate and hold the ignition switch in the Start
Remove the starter from the vehicle. See Starter in
position. Observe the voltmeter. If the reading is
the Removal and Installation section of this group for
above 0.2 volt, correct the poor starter to engine
the procedures. Then proceed as follows:
block ground contact.
(1) Remove the wire from the solenoid field coil
If the resistance tests detect no feed circuit prob-
terminal.
lems, remove the starter from the vehicle and see
8B - 6 STARTING SYSTEMS DN
DIAGNOSIS AND TESTING (Continued)
(2) Check for continuity between the solenoid ter- and 30. If OK, see Relay Circuit Test in the Diagno-
minal and the field coil terminal with a continuity sis and Testing section of this group. If not OK,
tester (Fig. 7). There should be continuity. If OK, go replace the faulty relay.
to Step 3. If not OK, replace the faulty starter assem-
bly.

Fig. 7 Continuity Test Between Solenoid Terminal

and Field Coil Terminal
(3) Check for continuity between the solenoid ter-
minal and the solenoid case (Fig. 8). There should be
continuity. If OK, go to Step 4. If not OK, replace the
faulty starter assembly. Fig. 9 Starter Relay
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
Fig. 8 Continuity Test Between Solenoid Terminal nected to the common feed terminal (30) in the ener-
and Solenoid Case gized position. This terminal supplies battery voltage
(4) Connect the solenoid field coil wire to the field to the starter solenoid field coils. There should be
coil terminal. continuity between the cavity for relay terminal 87
(5) Reinstall the starter. See Starter in the and the starter solenoid terminal at all times. If OK,
Removal and Installation section of this group for the go to Step 4. If not OK, repair the open circuit to the
procedures. starter solenoid as required.
(4) The coil battery terminal (86) is connected to
RELAY TEST the electromagnet in the relay. It is energized when
The starter relay (Fig. 9) is located in the Power the ignition switch is held in the Start position.
Distribution Center (PDC) in the engine compart- Check for battery voltage at the cavity for relay ter-
ment. Refer to the PDC label for starter relay iden- minal 86 with the ignition switch in the Start posi-
tification and location. tion, and no voltage when the ignition switch is
Remove the starter relay from the PDC to perform released to the On position. If OK, go to Step 5. If
the following tests. See Starter Relay in the Removal not OK, check for an open or short circuit to the igni-
and Installation section of this group for the proce- tion switch and repair, if required. If the circuit to
dures. the ignition switch is OK, see Ignition Switch Test in
(1) A relay in the de-energized position should the Diagnosis and Testing section of this group.
have continuity between terminals 87A and 30, and (5) The coil ground terminal (85) is connected to
no continuity between terminals 87 and 30. If OK, go the electromagnet in the relay. It is grounded
to Step 2. If not OK, replace the faulty relay. through the park/neutral position switch only when
(2) Resistance between terminals 85 and 86 (elec- the gearshift selector lever is in the Park or Neutral
tromagnet) should be 75 6 5 ohms. If OK, go to Step positions. Check for continuity to ground at the cav-
3. If not OK, replace the faulty relay. ity for relay terminal 85. If not OK, check for an
(3) Connect a battery to terminals 85 and 86. open or short circuit to the park/neutral position
There should now be continuity between terminals switch and repair, if required. If the circuit is OK,
30 and 87, and no continuity between terminals 87A
DN STARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)
see Park/Neutral Position Switch Test in the Diagno- (3) If the vehicle is so equipped, remove the front
sis and Testing section of this group. axle skid plate and skid plate crossmember. Refer to
Group 13 - Frame and Bumpers for the service pro-
PARK/NEUTRAL POSITION SWITCH TEST cedures.
(1) Place the transmission gear selector lever in (4) Remove the nut and lock washer from the
the Park position. starter mounting stud (Fig. 10).
(2) Disconnect and isolate the battery negative
cable.
(3) Raise and support the vehicle.
(4) Unplug the park/neutral position switch wire
harness connector.
(5) Check for continuity between the center switch
terminal and a good chassis ground. There should be
continuity. If OK, go to Step 6. If not OK, replace the
faulty switch.
(6) Move the transmission gear selector lever to
the Reverse position and check for continuity
between the center switch terminal and a good chas-
sis ground. There should be no continuity. If not OK,
replace the faulty switch.

IGNITION SWITCH TEST

WARNING: ON VEHICLES EQUIPPED WITH AIR- Fig. 10 Starter Remove/Install

BAGS, REFER TO GROUP 8M - PASSIVE (5) Remove the screw from the upper starter
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY mounting flange hole. Slide the automatic transmis-
STEERING WHEEL, STEERING COLUMN, OR sion cooler tube bracket forward on the tubes far
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR enough for clearance.
SERVICE. FAILURE TO TAKE THE PROPER PRE- (6) Move the starter towards the front of the vehi-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- cle until the starter gear housing nose clears the bell-
BAG DEPLOYMENT AND POSSIBLE PERSONAL housing. Then tilt the nose downwards and lower the
INJURY. starter far enough to access the starter solenoid wire
harness connector.
(1) Disconnect and isolate the battery negative
(7) Remove the two nuts that secure the battery
cable.
cable and solenoid feed wire to the terminals on the
(2) Remove the steering column shrouds and
starter solenoid. Remove the starter solenoid wire
unplug the ignition switch wire harness connector.
harness connector from the solenoid terminals.
Refer to Group 8D - Ignition Systems for the proce-
(8) Remove the starter motor from the vehicle.
dures.
(9) Reverse the removal procedures to install.
(3) With the ignition switch in the On position,
Tighten the starter hardware as follows:
check for continuity between the ignition switch ter-
• Lower mounting nut - 68 N·m (50 ft. lbs.)
minals 1 and 7. These are the terminals at each end
• Upper mounting screw - 68 N·m (50 ft. lbs.)
of the switch connector receptacle. There should be
• Battery cable terminal nut - 14 N·m (120 in.
no continuity. If OK, go to Step 4. If not OK, replace
lbs.)
the faulty switch.
• Solenoid wire harness terminal nut - 6 N·m (55
(4) With the ignition switch held in the Start posi-
in. lbs.).
tion, check for continuity between the ignition switch
terminals 1 and 7 again. There should now be conti-
STARTER RELAY
nuity. If not OK, replace the faulty switch.
(1) Disconnect and isolate the battery negative
cable.
REMOVAL AND INSTALLATION (2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 11).
STARTER (3) Refer to the label on the PDC for starter relay
(1) Disconnect and isolate the battery negative identification and location.
cable. (4) Unplug the starter relay from the PDC.
(2) Raise and support the vehicle.
8B - 8 STARTING SYSTEMS DN
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
STARTING SYSTEM

Starter and Solenoid

Manufacturer Nippon Denso
Engine Application 3.9L, 5.2L, 5.9L
Power Rating 1.4 Kilowatt
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Fig. 11 Power Distribution Center Number of Brushes 4
(5) Install the starter relay by aligning the relay Drive Type Reduction Gear Train
terminals with the cavities in the PDC and pushing
Free Running Test
the relay firmly into place. 11 Volts
Voltage
(6) Install the PDC cover.
(7) Connect the battery negative cable. Free Running Test
73 Amperes
(8) Test the relay operation. Amperage Draw
Free Running Test
3601 rpm
Minimum Speed
Solenoid Closing Voltage 7.5 Volts
*Cranking Amperage
125 to 250 Amperes
Draw Test
*Test at operating temperature. Cold engine, tight
(new) engine, or heavy oil will increase starter
amperage draw.