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Starter Motor

Starting and Charging › Starting System
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartStarter
ManufacturerCHY
OEM part #4801854AA
Price$180.00
NotesStarter Is Serviced Only As Assembly.

Labor

Replace — Manual Trans0.7 hr
Warranty 0.6 hrSkill B
Auto Trans1.0 hr
Warranty 0.0 hrSkill B
Procedures
Starter Motor: Specificationsreference
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STARTER MOTOR
Starter - Removal9 steps
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  1. Disconnect and isolate negative battery cable.
  2. Raise and support vehicle.
  3. Four Wheel Drive Equipped: Remove front propeller shaft.
  4. Remove two heat shield bolts (1) and remove starter heat shield (2).
  5. Remove solenoid nut (1) from mounting stud (3).
  6. After nut (1) has been removed, pull battery cable from mounting stud (3) while removing electrical connector (5) from solenoid terminal.
  7. Remove two starter mounting bolts (1).
  8. Remove starter assembly (2) from transmission.
  9. Rotate starter assembly to allow removal from vehicle.
Starter - Installation8 steps
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  1. Rotate starter assembly (2) to allow positioning into transmission.
  2. Install two starter mounting bolts (1) and tighten. Refer to Torque Specifications.
  3. Position battery cable assembly (2) onto stud (3) while pushing solenoid connector (5) onto solenoid terminal.
  4. Install nut (1) and tighten. Refer to Torque Specifications.
  5. Position starter heat shield (2) and install two bolts (1).
  6. Four Wheel Drive Equipped: Install front propeller shaft.
  7. Lower vehicle.
  8. Connect negative battery cable.
Starter Motor: Testing and Inspection10 steps
ℹ NOTE
This test can only be performed with starter motor removed from vehicle.
ℹ NOTE
Certain vehicles with certain engines may require starter motor removal for the following test.
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  1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation.
  2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
  3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used.
  4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
  5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications.
  6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications.
  7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. STARTER SOLENOID
  8. If necessary, remove starter motor from vehicle. Refer to Starter Motor Removal and Installation.
  9. Disconnect solenoid connector wiring from starter motor.
  10. Check for continuity between solenoid terminal (2) and solenoid case (3). There should be continuity. If not OK, replace faulty starter motor assembly.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
STARTER MOTOR
Engine Application3.7L2.8L Diesel
Power Rating1.2 Kilowatt2.2 Kilowatt
* Cranking Amperage Draw Test100 - 200 Amperes500 Amperes
* Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw. **The starter is equipped with permanent magnets. Never strike the starter case to attempt to loosen a sticking/stuck armature as permanent magnets may crack or break.
MOTOR - STARTER
STARTER MOTOR
Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle.
1. Remove starter motor from vehicle. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor
STARTER SOLENOID📷 1
Certain vehicles with certain engines may require starter motor removal for the following test.
1. If necessary, remove starter motor from vehicle. 2. Disconnect solenoid connector wiring from starter motor.
3. Check for continuity between solenoid terminal (2) and solenoid case (3). There should be continuity. If not OK, replace faulty starter motor assembly.
figure
REMOVAL - 2.8L DIESEL📷 2
1.   Disconnect and isolate negative battery cable.
  2.   Raise and support vehicle.
  3.   Four Wheel Drive Equipped: Remove front propeller shaft.
  4.   Remove solenoid nut (1) from mounting stud (3).
  5.   After nut (1) has been removed, pull battery cable from mounting stud (3) while removing electrical
connector (5) from solenoid terminal.
6. Remove two starter mounting bolts (2). 7. Remove starter assembly (1) from transmission. 8. Rotate starter assembly (1) to allow removal from vehicle.
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REMOVAL - 3.7L📷 3
1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. 3. Four Wheel Drive Equipped: Remove front propeller shaft.
4. Remove two heat shield bolts (1) and remove starter heat shield (2).
5. Remove solenoid nut (1) from mounting stud (3). 6. After nut (1) has been removed, pull battery cable from mounting stud (3) while removing electrical connector (5) from solenoid terminal.
7. Remove two starter mounting bolts (1). 8. Remove starter assembly (2) from transmission. 9. Rotate starter assembly to allow removal from vehicle.
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INSTALLATION - 2.8L DIESEL📷 4
1. Rotate starter assembly (1) to allow positioning into transmission. 2. Install two starter mounting bolts (2) and tighten. Refer to SPECIFICATIONS.
3. Position battery cable assembly (2) onto stud (3) while pushing solenoid connector (5) onto solenoid terminal. 4. Install nut (1) and tighten. Refer to SPECIFICATIONS. 5. Four Wheel Drive Equipped: Install front propeller shaft.
6. Lower vehicle. 7. Connect negative battery cable.
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INSTALLATION - 3.7L📷 2
1. Rotate starter assembly (2) to allow positioning into transmission. 2. Install two starter mounting bolts (1) and tighten. Refer toSPECIFICATIONS.
3. Position battery cable assembly (2) onto stud (3) while pushing solenoid connector (5) onto solenoid terminal. 4. Install nut (1) and tighten. Refer to SPECIFICATIONS.
  5.   Position starter heat shield (2) and install two bolts (1).
  6.   Four Wheel Drive Equipped: Install front propeller shaft.
  7.   Lower vehicle.
  8.   Connect negative battery cable.
RELAY - STARTER MOTOR
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