REMOVAL & INSTALLATION

Navajo and B Series Pick-up Models

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

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

   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.

MPV Models

2WD

Fig. 3: Pull the starter motor out just far enough to access the starter motor wiring connections

Fig. 4: Disconnect the starter motor wiring harness connectors

1. Disconnect the negative battery cable. Raise and safely support the vehicle.
2. Remove the starter motor mounting bolts.
3. Pull the starter motor out just far enough to disconnect the electrical connectors from the starter.
4. Remove the starter from the vehicle.
5. After removing the starter, examine the condition of the gear and flywheel teeth.

   Fig. 5: Carefully pull the starter motor forward and out from below the vehicle

   Fig. 6: After removing the starter motor, inspect the starter motor gear teeth . . .

   Fig. 7: . . . then inspect the flywheel gear teeth

   To install:

6. Place the starter in position, after cleaning the mounting flange surfaces.
7. Install and tighten the mounting bolts. Tighten the starter mounting bolts to 27–38 ft. lbs. (37–52 Nm) on 1994–95 vehicles and 24–33 ft. lbs. (32–46 Nm) on 1996–98 vehicles.
8. Connect all wiring connectors. Connect the negative battery cable.

4WD

1. Disconnect the negative battery cable.
2. Remove the drive belts.
3. Remove the power steering pump pulley.
4. Remove the alternator.
5. Raise and safely support the vehicle. Remove the splash shields.
6. Remove the power steering pump mounting bolts and position the pump aside, without disconnecting the power steering hoses.
7. Remove the automatic transmission cooler line brackets.
8. Mark the position of the driveshaft on the axle flange, and remove the front driveshaft.
9. Remove the wiring harness bracket and the automatic transmission cooler line bracket that is next to the starter.
10. Disconnect the electrical connectors from the starter.
11. Remove the fuel and brake line shield.
12. Remove the starter mounting bolts and remove the starter.

    To install:

13. Clean the mounting surface flanges. Place the starter motor into position and install the mounting bolts. Tighten the starter mounting bolts to 28–38 ft. lbs. (38–51 Nm).
14. Install the fuel and brake line shield.
15. Connect the starter motor wiring. Install the wiring harness bracket.
16. Connect the driveshaft.
17. Install the transmission cooler line brackets.
18. Install the power steering pump and the splash shields.
19. Lower the vehicle.
20. Install the alternator.
21. Install the power steering pump pulley.
22. Install and adjust the drive belts.
23. Connect the negative battery cable.