STARTING SYSTEMS

CONTENTS
page page
REMOVAL AND INSTALLATION
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
STARTER
2.5L DIESEL ENGINE
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Remove the ri ght front engi ne mount i nsul ator
and brackets. Refer to Group 9 - Engi nes for the pro-
cedures.
(4) Remove the starter front support bracket (Fi g.
1).
(5) Remove the strap that secures the starter heat
shi el d and remove the heat shi el d from the starter
(Fi g. 2).
(6) Remove the three bol ts that secure the starter
mounti ng fl ange to the transmi ssi on adapter pl ate.
(7) Lower the starter far enough to access and
remove the wi re harness connecti ons from the sol e-
noi d.
(8) Remove the starter from the vehi cl e.
(9) Reverse the removal procedures to i nstal l .
Ti ghten the starter hardware as fol l ows:
Battery cabl e termi nal nut - 27 Nm (20 ft. l bs.)
Starter mounti ng bol ts - 27 Nm (20 ft. l bs.)
Front starter support bracket nuts - 10 Nm (90
i n. l bs.)
Front starter support bracket bol t - 47 Nm (35
ft. l bs.).
STARTER RELAY
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC).
(3) Refer to the l abel on the PDC for starter rel ay
i denti fi cati on and l ocati on.
(4) Unpl ug the starter rel ay from the PDC.
(5) I nstal l the starter rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the PDC and pushi ng
the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(7) Connect the battery negati ve cabl e.
(8) Test the rel ay operati on.
Fig. 1 Starter Mounting - 2.5L Diesel Engine
Fig. 2 Starter Heat Shield Remove/Install
ZG STARTING SYSTEMS 8B - 1
SPECIFICATIONS
STARTING SYSTEM
Starter and Solenoid
Engine Application 2.5L Diesel
Power Rating 2.2 Kilowatt
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test Voltage 11.5 Volts
Free Running Test Maximum
Amperage Draw
160 Amperes
Free Running Test Minimum
Speed
5500 rpm
Solenoid Closing Maximum
Voltage
7.8 Volts
*Cranking Amperage Draw test 350 Amperes
*Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
8B - 2 STARTING SYSTEMS ZG