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NEGATIVECABLE SOLENOID TERMINAL STARTER SOLE-NOIDSTARTERMOTORSTARTERRELAY CON-NECTORGROUNDCIRCUITTHIS CIRCUIT GROUNDED ATALL TIMES (MAN. TRANS. ONLY)PARK/NEUTRAL POSITIONSWITCH (AUTO. TRANS. ONLY)CLUTCH PEDAL POSITIONSWITCH (MAN. TRANSMISSIONONLY)IGNITIONSWITCH IGNITIONFEEDBATTERYBATTERY RELAYFEEDPOSITIVECABLE
PL STARTING 8B - 1
STARTING
CONTENTS
page page
GENERAL INFORMATION
BOSCH STARTER ....................... 1
INTRODUCTION ........................ 1
SUPPLY CIRCUIT AND CONTROL CIRCUIT .... 1
DIAGNOSIS AND TESTING
FEED CIRCUIT RESISTANCE TEST .......... 3
CONTROL CIRCUIT TEST ................. 2
FEED CIRCUIT TEST ..................... 4
GENERAL INFORMATION
INTRODUCTION
The starting system (Fig. 1) has:
• Ignition switch
• Starter relay
• Neutral starting and back up switch
• Clutch pedal position switch
• Wiring harness
• Battery
• Starter motor with an integral solenoid
STARTING SYSTEM TEST ................. 5
REMOVAL AND INSTALLATION
SAFETY SWITCHES ..................... 7
STARTER RELAY ........................ 8
STARTER ............................. 7
SPECIFICATIONS
STARTER ............................. 8
TORQUE .............................. 8
NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
service procedures outlined can generally be
applied to either version. Exceptions to this rule
have been clearly identified as LHD, RHD, or Export
if a special illustration or procedure is required.
BOSCH STARTER
The Bosch is a permanent magnet starter motor. A
planetary gear train transmits power between starter
motor and pinion shaft. The fields have six permanent magnets. The starter system consists of two
separate circuits:
• A high amperage supply to feed the starter
motor.
• A low amperage circuit to control the starter
solenoid.
Fig. 1 Starting System
SUPPLY CIRCUIT AND CONTROL CIRCUIT
The starter system consists of two separate circuits:
• A high amperage supply to feed the starter
motor.
• A low amperage circuit to control the starter
solenoid.
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RELAY TERMINALSRELAY CAVITIES
8B - 2 STARTING PL
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
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANSMISSION IS IN THE PARK POSITION/NEUTRAL
WITH THE PARKING BRAKE APPLIED
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.
(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.
(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.
(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
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
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PL STARTING 8B - 3
DIAGNOSIS AND TESTING (Continued)
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
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,
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled
to prevent engine start while performing the following tests.
(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. 2). 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 (Fig. 2). 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.
3). 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.
VOLTMETER
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
Fig. 2 Test Battery Connection Resistance
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VOLTMETER
VOLTMETER
VOLTMETER
8B - 4 STARTING PL
DIAGNOSIS AND TESTING (Continued)
Fig. 3 Test Ground Circuit Resistance
(3) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal (Fig. 4). 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. 5).
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, replace the starter motor.
FEED CIRCUIT TEST
The following procedure will require a suitable
volt-ampere tester (Fig. 6).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Connect a volt-ampere tester to the battery ter-
minals (Fig. 7). Refer to the operating instructions
provided with the tester being used.
(2) To disable the ignition and fuel systems, dis-
connect 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. The 2.5L Diesel Engine, to disable the
engine from starting, disconnect wire connector from
the Fuel Solenoid.
Fig. 4 Test Starter Motor Ground
Fig. 5 Test Battery Positive Cable Resistance
(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.
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.
6).
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POSITIVE CLAMP NEGATIVE CLAMPINDUCTION AMMETERCLAMP
PL STARTING 8B - 5
DIAGNOSIS AND TESTING (Continued)
STARTING SYSTEM TEST
For circuit descriptions and diagrams, refer to
8W-21, Starting System in Group 8W, Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 6 Volt Ampere Tester
INSPECTION
Before removing any unit from the starting system
for repair or diagnosis, perform the following inspections:
• Battery - Visually inspect the battery for indi-
cations of physical damage and loose or corroded
cable connections. Determine the state-of-charge and
cranking capacity of the battery. Charge or replace
the battery, if required. Refer to Group 8A, Battery
for more information.
• Ignition Switch - Visually inspect the ignition
switch for indications of physical damage and loose
or corroded wire harness connections.
• Clutch Pedal Position Switch - Visually
inspect the clutch pedal position switch for indications of physical damage and loose or corroded wire
Fig. 7 Volt-Ampere Tester Connections
• 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.
harness connections.
• Park/Neutral Position Switch - Visually
inspect the park/neutral position switch for indications of physical damage and loose or corroded wire
harness connections.
• Starter Relay - Visually inspect the starter
relay for indications of physical damage and loose or
corroded wire harness connections.
• Starter - Visually inspect the starter for indi-
cations of physical damage and loose or corroded wire
harness connections.
• Starter Solenoid - Visually inspect the starter
solenoid for indications of physical damage and loose
or corroded wire harness connections.
• Wiring - Visually inspect the wire harness for
damage. Repair or replace any faulty wiring, as
required.
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8B - 6 STARTING PL
DIAGNOSIS AND TESTING (Continued)
STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty.
STARTER ENGAGES, FAILS TO
TURN ENGINE.
STARTER ENGAGES, SPINS OUT
BEFORE ENGINE STARTS.
STARTER DOES NOT
DISENGAGE.
2. Starting circuit wiring faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position switch (auto
trans) faulty or mis-adjusted.
6. Clutch pedal position switch (man
trans) faulty.
7. Starter solenoid faulty.
8. Starter assembly faulty.
1. Battery discharged or faulty.
2. Starting circuit wiring faulty.
3. Starter assembly faulty.
4. Engine seized.
1. Broken teeth on starter ring gear.
2. Starter assembly faulty.
1. Starter improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter assembly faulty.
1. Refer to Group 8A, Battery.
Charge or replace battery, if required.
2. Refer to Feed Circuit Resistance
Test and Feed Circuit Test in this
section.
3. Refer to Relay Test, in this section.
Replace relay, if necessary.
4. Refer to Ignition Switch Test, in
Group 8D Ignition System or Group
8W, Wiring Diagrams. Replace
switch, if necessary.
5. Refer Park/Neutral Position Switch
Test, in Group 21, Transaxle.
Replace switch, if necessary.
6. Refer to Clutch Pedal Position
Switch Test, in Group 6, Clutch.
Replace switch, if necessary.
7. Refer to Solenoid Test, in this
section. Replace starter assembly, if
necessary.
8. If all other starting system
components and circuits check OK,
replace starter assembly.
1. Refer to Group 8A, Battery.
Charge or replace battery as
necessary.
2. Refer to the Feed Circuit
Resistance Test and the Feed Circuit
Test in this section. Repair as
necessary.
3. If all other starting system
components and circuits check OK,
replace starter assembly.
4. Refer to Group 9 Engine, for
diagnostic and service procedures.
1. Remove starter. Inspect ring gear
and replace if necessary.
2. If all other starting system
components and circuits check OK,
replace starter assembly.
1. Install starter. Tighten starter
mounting hardware to correct torque
specifications.
2. Refer to Relay Test, in this section.
Replace relay, if necessary.
3. Refer to Ignition Switch Test, in
Group 8D, Ignition System. Replace
switch, if necessary.
4. If all other starting system
components and circuits check OK,
replace starter assembly.
Page 7
TRANSAXLEHOUSING GROUND CABLE
FRONT ENGINEMOUNTINGBRACKET
PL STARTING 8B - 7
REMOVAL AND INSTALLATION
SAFETY SWITCHES
NEGATIVEBATTERYPOST BATTERY TESTINDICATOR NEGATIVECABLE
For Removal and Installation of the:
• Clutch Position Switch, refer to Group 6, Clutch.
• Park/Neutral Switch, refer to Group 21, Tran-
saxle.
STARTER
REMOVAL
(1) Disconnect battery negative cable (Fig. 8).
(2) Raise vehicle.
(3) Vehicles equipped with A/C:
(a) Using a floor jack or jack stand, support the
engine and transmission assembly so they will not
rotate.
(b) Remove the front engine mount bolt from the
insulator and front crossmember mounting bracket
(Fig. 9).
(c) Lower the front of the engine, rotate the
engine forward, allowing easier removal of starter
motor.
(4) For easier servicing, do not remove the wiring
from starter at this time.
(5) Remove two bolts attaching starter to trans-
mission housing (Fig. 10).
(6) Remove starter/starter solenoid assembly from
transmission housing. Position the starter to gain
access to the wiring connectors.
(7) Remove the battery positive cable nut and
remove the battery positive and generator output
wire from the starter (Fig. 11).
(8) Disconnect push-on solenoid connector.
(9) Position the starter vertically such that the
pinion end faces downward.
(10) Remove the starter through the bottom of the
vehicle. Move aside A/C plumbing as necessary.
Fig. 9 Front Engine Mount Bolt Removal
Fig. 8 Battery Cable Removal and Installation
INSTALLATION
(1) Clean corrosion/dirt from the cable and wire
terminals before installing wiring to the solenoid.
(2) Connect the battery positive and generator out-
put wire to the starter solenoid post (Fig. 11).
Fig. 10 Starter Removal
CAUTION: It is critical that the generator output terminal be connected to the battery positive terminal
of the starter solenoid, for proper operation of the
charging and cranking systems.
(3) Connect the push-on solenoid connector.
(4) Position the starter face into transmission
housing. Support starter in pilot and start the top
bolt (Fig. 10).
(5) Attach ground cable to lower mounting bolt
and start bolt.
(6) Ensure the proper starter alignment before
tightening the starter mounting bolts to 54 N·m (40
ft. lbs.) torque.
(7) Vehicles equipped with A/C:
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B+ POSTGENERATOR OUTPUT WIREPUSH ON SOLENOID CON-NECTORB+ BATTERY POSITIVE WIRE
8B - 8 STARTING PL
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
STARTER
Manufacturer BOSCH
Engine Application 2.0L OHC - DOHC
Power rating 0 .95 Kw
Voltage 12 VOLTS
No. of Fields 6
No. of Poles 6
Brushes 4
Drive Planetary Gear Train
Cranking Amperage Draw
test
150 - 280 Amps.
Fig. 11 Wire Connection
(a) Using a floor jack or jack stand, raise the
engine and transmission assembly to the original
position.
(b) Install the front engine mount bolt through
the insulator and front crossmember mounting
bracket (Fig. 9).
(c) Tighten bolt to 54 N·m (40 ft. lbs.) torque.
(8) Lower vehicle and connect battery cables.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
TORQUE
DESCRIPTION TORQUE
Starter Mounting Bolts ........54N·m(40ft.lbs.)
Starter Solenoid Battery Nut . . . 10 N·m (90 in. lbs.)
STARTER RELAY
The relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for relay location.
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