Testing, removal and installation of starter solenoid

GENERAL INFORMATION

If the starter solenoid is damaged, the starter pinion does not engage with the flywheel ring gear. As a result, the starter cannot crank the engine. This fault occurs more often than a fault in the starter motor.

Test without removal

PROCEDURE

1. Set the gear selector lever to neutral.

2. Test condition: The battery must be fully charged.

3. Briefly connect terminal 30 (thick positive cable) and terminal 50 (thin cable to the ignition switch) of the starter. The starter pinion must move forward (click) and the starter must crank. If this does not happen, remove the starter and test it off the vehicle.

Test with removal

PROCEDURE

1. Remove the starter.

2. Connect the battery to the starter and solenoid with a auxiliary (starting) cable as follows. Connect the negative battery terminal to the starter housing. Briefly apply the cable from the positive battery terminal to terminal 50 of the solenoid. The starter pinion must move forward.

CAUTION

The positive cable must be connected to terminal 50 for no more than 10 s, otherwise the relay winding will burn out.

3. If the pinion moves forward but the starter does not rotate, the starter motor must be repaired.

4. If the pinion does not move forward, replace the starter solenoid. REMOVAL

PROCEDURE

1. Remove the starter.

2. Unscrew the 2 solenoid mounting bolts.

3. Disconnect and remove the solenoid from the starter. INSTALLATION

PROCEDURE

1. Apply suitable sealant to the mating surface (F) of the starter.

2. Connect the solenoid to the shift lever in the starter, then secure with nuts.

3. Connect the wire to the solenoid.

4. Test the solenoid again as described above.

5. Install the starter.