NS STARTING SYSTEMS 8B - 1
STARTING SYSTEMS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
STARTING SYSTEM .......................1
SUPPLY CIRCUIT AND CONTROL CIRCUIT.....1
DIAGNOSIS AND TESTING
CONTROL CIRCUIT TEST...................1
FEED CIRCUIT RESISTANCE TEST............4
FEED CIRCUIT TEST.......................5
DESCRIPTION AND OPERATION
STARTING SYSTEM
DESCRIPTION
The starting system has:
• Ignition switch
• Starter relay
• Powertrain Control Module (PCM) double start
override
• Neutral starting and back up switch with auto-
matic transmissions only
• Wiring harness
• Battery
• Starter motor with an integral solenoid
• Positive Temperature Coefficient (PTC) is the
circuit protection for the ignition feed to the starter
relay coil. The PTC is located in the Junction Block.
OPERATION
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
REMOVAL AND INSTALLATION
STARTER—2.4L ENGINE ...................6
STARTER—3.0L ENGINE ...................6
STARTER—3.3/3.8L ENGINE ................7
SPECIFICATIONS
STARTER ...............................8
TORQUE ................................8
DIAGNOSIS AND TESTING
CONTROL CIRCUIT TEST
The starter control circuit has:
• Starter solenoid
• Starter relay
• Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
• Clutch Pedal Position Switch with manual
transmissions
• Ignition switch
• Battery
• All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
• To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the in the Power Distribution Center
(PDC). Refer to the PDC cover for the proper relay
location.
STARTER SOLENOID
SUPPLY CIRCUIT AND CONTROL CIRCUIT
DESCRIPTION
The starter system consists of two separate cir-
cuits.
OPERATION
• A high amperage supply to feed the starter
motor.
• A low amperage circuit to control the starter
solenoid.
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE performing the starter relay test.
(3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(5) Lower the vehicle.
8B - 2 STARTING SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
Fig. 1 Starting System Schematic
1 – NEGATIVE CABLE
2 – SOLENOID TERMINAL
3 – STARTER SOLENOID
4–STARTER
5 – STARTER RELAY CONNECTOR
6 – PCM
7 – CIRCUIT GROUNDED ALL TIMES (MAN. TRANS. ONLY)
8 – NEUTRAL SAFETY SWITCH (AUTO. TRANS. ONLY)
9 – CLUTCH PEDAL MOUNTED STARTER INTERLOCK SWITCH
10 – IGNITION SWITCH
11 – BATTERY
12 – IGNITION FEED
13 – BATTERY RELAY FEED
14 – POSITIVE CABLE
(6) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(7) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
Fig. 2 Supply and Control Circuit Schematic
1 – SOLENOID TERMINAL
2 – STARTER SOLENOID
3 – STARTER MOTOR
4 – STARTER RELAY CONNECTOR
5 – PCM
6 – GROUND CIRCUIT
7 – TRANSMISSION RANGE SENSOR/PARK/NEUTRAL SENSE
8 – IGNITION SWITCH
9 – IGNITION FEED
10 – BATTERY
11 – BATTERY RELAY FEED
12 – POSITIVE CABLE
13 – NEGATIVE CABLE
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not or solenoid chatters, check
wiring and connectors from starter relay to starter
solenoid for loose or corroded connections. Particularly at starter terminals.
(c) Repeat test. If engine still fails to crank properly, trouble is within starter or starter mounted
solenoid, and replace starter.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL
WITH THE PARKING BRAKE APPLIED
NS STARTING SYSTEMS 8B - 3
DIAGNOSIS AND TESTING (Continued)
RELAY TEST
The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (electromagnet) should be 75 65 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 86 and
a ground lead to terminal 85 to energize the relay.
The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity
between terminals 87A and 30. If OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
TERMINAL LEGEND
Starter Relay
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position. On
vehicles with a manual transmission, the clutch
pedal must be fully depressed for this test. Check for
battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position, and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK with an
automatic transmission, check for an open or short
circuit to the ignition switch and repair, if required.
If the circuit to the ignition switch is OK, see the
Ignition Switch Test procedure in this group. If not
OK with a manual transmission, check the circuit
between the relay and the clutch pedal position
switch for an open or a short. If the circuit is OK, see
the Clutch Pedal Position Switch Test procedure in
this group.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift
selector lever is in the Park or Neutral positions. On
vehicles with a manual transmission, it is grounded
at all times. Check for continuity to ground at the
cavity for relay terminal 85. If not OK with an automatic transmission, check for an open or short circuit
to the park/neutral position switch and repair, if
required. If the circuit is OK, see the Park/Neutral
Position Switch Test procedure in this group. If not
OK with a manual transmission, repair the circuit to
ground as required.
SAFETY SWITCHES
For diagnostics,
• Clutch Pedal Position Switch, refer to Group 6,
Clutch.
• Park/Neutral Position Switch, refer to Group 21,
Transaxle
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 connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
IGNITION SWITCH
After testing starter solenoid and relay, test ignition switch and wiring. Refer to Group 8D, Ignition
Systems or Group 8W, Wiring Diagrams. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
Refer to Group 8A, Battery for proper procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W, Wiring Diagrams,
8B - 4 STARTING SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diagnostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 3). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, correct poor contact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the battery positive cable clamp. Rotate and hold the ignition switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor contact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point (Fig.
4). Rotate and hold the ignition switch in the
START position. If voltage reads above 0.2 volt,
correct poor contact at ground cable attaching
point. If voltage reading is still above 0.2 volt after
correcting poor contacts, replace ground cable.
(3) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 5). Hold the ignition switch
key in the START position. If voltage reads above 0.2
volt, correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to battery cable terminal on starter solenoid (Fig. 6).
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at battery cable to solenoid connection. If reading is still above 0.2 volt after correcting poor contacts, replace battery positive cable.
(b) If resistance tests do not detect feed circuit
failures, remove the starter motor and go to
Starter Solenoid Test in this Group.
Fig. 3 Test Battery Connection Resistance
1 – VOLTMETER
2 – POWER DISTRIBUTION CENTER
3 – POWERTRAIN CONTROL MODULE
4 – DRIVER’S SIDE FENDER
Fig. 4 Test Ground Circuit Resistance
1 – ENGINE GROUND
2 – POWERTRAIN CONTROL MODULE
3 – POWER DISTRIBUTION CENTER
4 – DRIVER’S SIDE FENDER
5 – VOLTMETER
NS STARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)
FEED CIRCUIT TEST
The following procedure will require a suitable
volt-ampere tester (Fig. 7).
Fig. 7 Volt Ampere Tester
CAUTION: Before performing any starter tests, the
Fig. 5 Test Starter Motor Ground
1 – STARTER MOTOR
2 – POWER DISTRIBUTION CENTER
3 – DRIVER’S SIDE FENDER
4 – POWERTRAIN CONTROL MODULE
5 – VOLTMETER
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery terminals (Fig. 8). Refer to the operating instructions
provided with the tester being used.
Fig. 6 Test Battery Positive Cable Resistance
1 – POWER DISTRIBUTION CENTER
2 – POWERTRAIN CONTROL MODULE
3 – DRIVER’S SIDE FENDER
4 – STARTER MOTOR
5 – SOLENOID
6 – BATTERY TERMINAL
Fig. 8 Volt-Ampere Tester Connections
1 – POSITIVE CLAMP
2 – NEGATIVE CLAMP
3 – INDUCTION AMMETER CLAMP
(2) To disable the ignition and fuel systems, disconnect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Center (PDC). Refer to the PDC cover for proper relay
location.
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
position or with the clutch pedal depressed and SET
parking brake.
8B - 6 STARTING SYSTEMS NS
DIAGNOSIS AND TESTING (Continued)
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
7).
• If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps or the Diesel engine
above 450 amps, check for engine seizing or faulty
starter.
• If voltage reads 12.4 volts or greater and amperage reads 0 to 10 amps, check for corroded cables
and/or bad connections.
• Voltage below 9.6 volts and amperage draw
above 300 amps or Diesel engine above 500 amps,
the problem is the starter. Replace the starter refer
to starter removal.
(5) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect ASD relay or the Fuel Solenoid. Start the vehicle several times to assure the
problem has been corrected.
1 – PDC
2 – POSITIVE
3 – NEGATIVE
Fig. 9 Battery Negative Cable
REMOVAL AND INSTALLATION
STARTER—2.4L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable (Fig. 9).
(3) Hoist and support vehicle on safety stands.
(4) Disconnect solenoid wire connector from terminal.
(5) Remove nut holding B+ wire to terminal.
(6) Disconnect solenoid and B+ wires from starter
terminals.
(7) Remove bolts holding starter to transaxle bellhousing (Fig. 10).
(8) Remove starter.
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install bolts to hold starter to transaxle bellhousing.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Connect solenoid wire connector onto terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
Fig. 10 Starter - 2.4L Engine Wire Connectors
1 – B+ CONNECTOR
2 – SOLENOID CONNECTOR
STARTER—3.0L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect battery negative cable (Fig. 9).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding solenoid wire to terminal
(Fig. 11).
(5) Remove nut holding B+ wire to terminal (Fig.
6)
(6) Disconnect solenoid and B+ wires from starter
terminals.
(7) Remove bolts holding starter to transaxle bell-
housing (Fig. 12).
(8) Remove starter.
NS STARTING SYSTEMS 8B - 7
REMOVAL AND INSTALLATION (Continued)
STARTER—3.3/3.8L ENGINE
REMOVAL
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable (Fig. 9).
(3) Hoist and support vehicle on safety stands.
(4) Remove nut holding B+ terminal to starter
solenoid (Fig. 13).
Fig. 11 Wire Connectors
1 – B(+) CONNECTOR
2 – SOLENOID BLADE CONNECTOR
3 – STARTER MOTOR
4 – DRAIN TUBE
Fig. 12 Starter–3.0L Engine
1 – NIPPONDENSO STARTER MOTOR
INSTALLATION
(1) Place starter in position on vehicle.
(2) Install bolts to hold starter to transaxle bell-
housing.
(3) Place solenoid and B+ wires in position on
starter terminals.
(4) Install nut to hold B+ wire to terminal.
(5) Install nut to hold solenoid wire to terminal.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
Fig. 13 Starter - 3.3 / 3.8L Engine Wire Connectors
1 – B+ CONNECTOR
2 – SOLENOID CONNECTOR
(5) Disconnect solenoid connector from starter.
(6) Remove bolts holding starter to transaxle bell-
housing (Fig. 14).
Fig. 14 Starter Bolts
1–STARTER
2 – BOLTS
3 – TRANSAXLE
4 – ENGINE MOUNT
8B - 8 STARTING SYSTEMS NS
REMOVAL AND INSTALLATION (Continued)
(7) Remove starter from bellhousing (Fig. 15).
Fig. 15 Starter–3.3/3.8L Engine
1 – BELL HOUSING PLATE
2 – FLYWHEEL
3 – ENGINE MOUNT
4–STARTER
5 – SPACER
(8) Separate starter spacer from transaxle bell-
housing.
INSTALLATION
(1) Place starter spacer in position on transaxle
bellhousing, flange toward flywheel.
(2) Place starter in position on bellhousing.
(3) Install bolts to hold starter to transaxle bell-
housing.
(4) Connect solenoid connector into starter.
(5) Install nut to hold B+ terminal to starter sole-
noid.
(6) Lower vehicle.
(7) Connect battery negative cable.
(8) Verify starter operation.
SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.0L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
150 - 200 Amps.
TORQUE
DESCRIPTION TORQUE
Starter Mounting Bolts ....... 54N·m(40ft.lbs.)
Starter Solenoid Battery Nut . . 10 N·m (90 in. lbs.)
NS/GS STARTING SYSTEM 8B - 1
STARTING SYSTEM
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION
STARTER — 2.0L GAS.....................1
STARTER – 2.4L GAS......................1
STARTER – 2.5L DIESEL – LHD .............2
REMOVAL AND INSTALLATION
STARTER — 2.0L GAS
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the upper starter motor retaining
bolts.
(3) Raise vehicle on hoist.
(4) Disconnect starter motor electrical.
(5) Remove the heat shield.
(6) Remove the lower starter motor retaining bolt.
(7) Lower the vehicle on hoist.
(8) Working from above, remove the starter from
the vehicle.
INSTALLATION
(1) Install the starter and upper retaining bolts to
hold starter in position.
(2) Raise the vehicle on hoist.
(3) Install the lower starter retaining bolt. Torque
bolt to 54 N•m (40 ft. lbs.).
(4) Install the heat shield.
(5) Connect the starter motor electrical.
(6) Lower the vehicle from hoist.
(7) Torque the upper starter motor retaining bolts
to 54 N•m (40 ft. lbs.).
(8) Connect the negative battery cable.
STARTER – 2.4L GAS
2.4L ENGINE - With Manual Transaxle
REMOVAL
(1) Disconnect the battery negative cable.
(2) Raise the vehicle on hoist.
(3) Disconnect the solenoid wire connector from
terminal.
(4) Remove the nut holding B+ wire to terminal.
(5) Disconnect the solenoid and B+ wires from
starter terminals.
(6) Remove the bolts holding starter to transaxle
bellhousing (Fig. 1).
STARTER – 2.5L DIESEL – RHD .............3
STARTER RELAY .........................4
SPECIFICATIONS
TORQUE SPECIFICATIONS..................5
(7) Remove the starter from vehicle.
INSTALLATION
(1) Place the starter in position on vehicle.
(2) Install the starter attaching bolts to transaxle
bellhousing. Torque bolts to 54 N•m (40 ft. lbs.).
(3) Place the solenoid and B+ wires in position on
starter terminals.
(4) Install the nut to hold B+ wire to terminal.
(5) Connect the solenoid wire connector onto terminal.
(6) Lower the vehicle from hoist.
(7) Connect the battery negative cable.
2.4L ENGINE - With Automatic Transaxle
REMOVAL
(1) Disconnect the battery negative cable.
(2) Raise the vehicle on hoist
(3) Disconnect the solenoid wire connector from
terminal.
(4) Remove the nut holding B+ wire to terminal.
(5) Disconnect the solenoid and B+ wires from
starter terminals.
(6) Remove the bolts holding starter to transaxle
bellhousing (Fig. 2).
(7) Remove the starter from vehicle.
INSTALLATION
(1) Place the starter in position on vehicle.
(2) Install the starter attaching bolts to transaxle
bellhousing. Torque bolts to 54 N•m (40 ft. lbs.)
(3) Place the solenoid and B+ wires in position on
starter terminals.
(4) Install the nut to hold B+ wire to terminal.
(5) Connect the solenoid wire connector onto terminal.
(6) Lower the vehicle from hoist.
(7) Connect the battery negative cable.
8B - 2 STARTING SYSTEM NS/GS
REMOVAL AND INSTALLATION (Continued)
1 – TRANSAXLE
Fig. 1 Starter - 2.4L Engine with Manual Transaxle
Fig. 2 Starter - 2.4L Engine with Automatic Transaxle
1 – TRANSAXLE
STARTER – 2.5L DIESEL – LHD
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise the vehicle on a hoist.
(3) Disconnect the starter motor electrical.
(4) Remove the oil return hose from the turbocharger (Fig. 3).
(5) Remove the rear starter support bracket.
(6) Remove the turbo support brace bolt from
exhaust inlet pipe. Loosen bolt securing brace to
engine block and position brace out of the way.
NS/GS STARTING SYSTEM 8B - 3
REMOVAL AND INSTALLATION (Continued)
(8) Remove the right rear steering gear mounting
nut and bolt assembly to allow starter motor
removal.
INSTALLATION
(1) Install the starter and mounting bolts. Torque
to 24 N•m (17 ft. lbs.).
(2) Install the turbo support brace.
(3) Install the rear starter support bracket. Torque
bolt to 47 N•m (35 ft. lbs.) and nuts to 11 N•m(8ft.
lbs.).
(4) Install the oil return hose on the turbocharger
(Fig. 3).
(5) Connect the starter motor electrical.
(6) Install the right rear steering gear mounting
nut and bolt assembly and Torque to 183 N•m (135
ft. lbs.).
(7) Lower the vehicle from the hoist.
(8) Connect the negative battery cable.
Fig. 3 Turbocharger Oil Return Hose
1 – FRONT SUSPENSION CRADLE
2 – TURBOCHARGER ASSEMBLY
3 – CRADLE SUPPORT BRACE
4 – TURBOCHARGER OIL RETURN LINE
5 – OIL RETURN LINE RETAINING BOLTS
(7) Remove the starter mounting bolts (Fig. 4).
Fig. 4 2.5L Diesel Starter
1 – WIRE CONNECTOR TERMINALS
2–STARTER
3 – BOLTS (3)
STARTER – 2.5L DIESEL – RHD
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise the vehicle on a hoist.
(3) Remove the right front wheel/tire assembly.
(4) Remove the spindle stop bolt.
(5) Remove the tie rod end from the spindle. Refer
to Group 19, Steering Gear for procedure.
(6) Remove the lower balljoint throughbolt.
(7) Separate the lower balljoint from the spindle
assembly.
(8) Drain transaxle fluid. See Group 21 for procedure.
CAUTION: DO NOT LET AXLESHAFT HANG FROM
INNER CV JOINT. SUPPORT THE AXLE SHAFT
WITH MECHANIC WIRE.
(9) Remove the half-shaft from the transmission.
See Group 3, Differential and Driveline for procedure.
(10) Disconnect the starter motor electrical.
(11) Remove the oil return hose from the turbocharger (Fig. 5).
(12) Remove the rear starter support bracket.
(13) Remove the turbo support brace bolt from
exhaust inlet pipe. Loosen bolt securing brace to
engine block and position brace out of the way.
(14) Remove the starter motor retaining bolts (Fig.
6).
(15) Remove starter motor from vehicle.
8B - 4 STARTING SYSTEM NS/GS
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install the starter and mounting bolts. Torque
to 24 N•m (17 ft. lbs.).
(2) Install the turbo support brace.
(3) Install the rear starter support bracket. Torque
bolt to 47 N•m (35 ft. lbs.) and nuts to 11 N•m(8ft.
lbs.).
(4) Install the oil return hose to the turbocharger
(Fig. 5).
(5) Connect the starter motor electrical.
(6) Install the axle shaft in the transmission. Refer
to Group 3, Differential and Driveline for procedure.
(7) Connect the lower balljoint to the spindle
assembly.
(8) Install the lower balljoint throughbolt and
Torque nut. Refer to Group 2, Suspension for torque
specifications.
(9) Install the tie rod end to the spindle and
Torque nut. Refer to Group 19, Steering Gear for procedure.
Fig. 5 Turbocharger Oil Return Hose
1 – FRONT SUSPENSION CRADLE
2 – TURBOCHARGER ASSEMBLY
3 – CRADLE SUPPORT BRACE
4 – TURBOCHARGER OIL RETURN LINE
5 – OIL RETURN LINE RETAINING BOLTS
(10) Install the spindle stop bolt and Torque. Refer
to Group 2, Suspension for torque specifications.
(11) Install the rightside wheel/tire assembly.
Refer to Group 22, Tires and Wheels for specifications.
(12) Re-fill transaxle fluid. See Group 21, Transaxle and Power Transfer Unit for procedure.
(13) Lower the vehicle on hoist.
(14) Connect the negative battery cable.
Fig. 6 2.5L Diesel Starter
1 – WIRE CONNECTOR TERMINALS
2–STARTER
3 – BOLTS (3)
STARTER RELAY
There are two starter relay’s used on this vehicle.
One is located on the starter motor, this relay is not
serviced separately from the starter motor. If this
relay becomes inoperative the entire starter motor
must be replaced. The other starter relay is located
in the Power Distribution Center (PDC), which can
be found in the engine compartment. This relay is
serviceable and can be replaced by simply pulling
straight from the PDC. Be certain replacement relay
has the same current rating (20 Amps) as the original relay. Refer to Starter Relay Test in the Gasoline
Engine Service Manual.
NS/GS STARTING SYSTEM 8B - 5
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
2.5L Diesel Starter Mounting Bolts
Bolts (3) ................. 24N·m(212 in. lbs.)
2.5L Diesel Starter Support Bracket
Bolt (1) ................... 47N·m(35ft.lbs.)
Nuts (2) .................. 11N·m(97in.lbs.)
Steering Gear Mounting Bolt
Bolt&Nut .............. 183N·m(135 ft. lbs.)
2.0L/2.4L Gas Starter Mounting Bolts
Bolts (3) .................. 54N·m(40ft.lbs.)
Battery (B+) Terminal Connection On Starter
Nut...................... 10N·m(90in.lbs.)
Fig. 7 Starting System Components
1 – NEGATIVE CABLE
2 – SOLENOID TERMINAL
3 – STARTER SOLENOID
4–STARTER
5 – STARTER RELAY CONNECTOR
6 – PCM
7 – CIRCUIT GROUNDED ALL TIMES (MAN. TRANS. ONLY)
8 – NEUTRAL SAFETY SWITCH (AUTO. TRANS. ONLY)
9 – CLUTCH PEDAL MOUNTED STARTER INTERLOCK SWITCH
10 – IGNITION SWITCH
11 – BATTERY
12 – IGNITION FEED
13 – BATTERY RELAY FEED
14 – POSITIVE CABLE
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