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Starter

TESTING

Navajo Models

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. 1: Starter system inspection chart

Fig. 2: Starter system evaluation procedure chart

Pickup and MPV Models

Fig. 3: Starter motor solenoid terminal identifications

ON VEHICLE TEST

Fig. 4: Measuring the voltage between terminal S and ground, using a voltmeter

Be sure that the battery is fully charged before starting this test

  1. Turn the ignition switch to the START position.
  2. Verify that the starter motor operates.
  3. If the starter motor does not operate, measure the voltage between terminal S and ground, using a voltmeter.
  4. If the voltage measures 8V or more, the starter is not working properly.
  5. If the voltage measures less than 8V, the wiring harness is the fault.

    NOTE: If the magnetic switch is hot, it may not function even though the voltage is standard or greater.

MAGNETIC SWITCH PULL OUT TEST

Fig. 5: Apply battery positive voltage to terminal S and body ground

Fig. 6: Measure the pinion gap while it is pulled out — 3.0L engine

  1. Apply battery positive voltage to terminal S and body ground, verify that the pinion is pulled out.
  2. On 3.0L engines only, measure the pinion gap while the pinion is pulled out. It should measure 0.02–0.08 inch (0.5–2.0 mm).
  3. If not within specifications, adjust with an adjustment washer (drive housing front cover-magnetic switch).
RETURN TEST
  1. Disengage the motor wire from terminal M, and then connect battery power to terminal M and ground the body.
  2. Using a small prying tool, pull out the overrunning clutch. Verify that the overrunning clutch returns to its original position when released.
NO-LOAD TEST

Fig. 7: Schematics for connecting the battery, starter, ammeter and voltmeter

  1. Verify that the battery is fully charged.
  2. Connect the battery, starter, ammeter and voltmeter as illustrated.
  3. Operate the starter and verify that it turns smoothly.
  4. Measure the voltage and current while the starter is operating.

    2.6L engine:

    3.0L engine:

  5. If not as specified, replace the starter motor.

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