Service Procedure

I. BATTERY POSITIVE CABLE INSPECTION

CAUTION:
THE BATTERY NEGATIVE CABLE MUST BE DISCONNECTED FIRST TO PREVENT ARCING.

1. Disconnect the battery negative cable.





CAUTION:
MAKE SURE THE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

2. Raise the vehicle on a hoist.

CAUTION:
BE CAREFUL NOT TO CONTACT HOT EXHAUST PIPE.





3. Remove starter motor splash shield retainer by inserting a small screwdriver in the flat and rotate screwdriver to remove the center pin. (Refer to illustration.)

4. With center pin removed, remove outer portion of the starter motor splash shield retainer.

5. Remove starter motor splash shield by lifting upward and pulling backward at the top of the shield to remove shield from the starter motor.

6. Visually inspect battery positive cable terminal at the starter motor solenoid.





a. If rubber insulator on battery positive cable terminal is contacting the starter motor solenoid metal housing as indicated by the large arrow in the illustration, proceed to "II. ADJUSTING BATTERY POSITIVE CABLE TERMINAL AT STARTER MOTOR" procedure in this bulletin.

b. If rubber insulator on battery positive cable terminal is not contacting the starter motor solenoid metal housing, use feeler gages stacked to 2 mm (0.080 in.) and measure the clearance between the starter motor solenoid metal housing and the largest diameter of the rubber insulator on the battery positive cable terminal. (Refer to illustration.)

^ If clearance is less than 2 mm (0.080 in.) proceed to "II. ADJUSTING BATTERY POSITIVE CABLE TERMINAL AT STARTER MOTOR" procedure in this bulletin.

^ If the clearance is over 2 mm (0.080 in.) proceed to next step of this procedure.

7. Install starter motor splash shield and retainer (PN14039420).

8. Lower vehicle on hoist.

9. Connect battery negative cable.

Torque: 17 N-m (151 in.lbs)

10. Affix the campaign completion label as outlined "CAMPAIGN COMPLETION LABEL."

II. ADJUSTING BATTERY POSITIVE CABLE TERMINAL AT STARTER MOTOR





1. Prying upwards using a wide bladed screwdriver, with the blade inserted between the largest diameter of the battery positive cable terminal's rubber insulator and starter motor solenoid metal housing (refer to illustration), obtain between 2 to 6 mm (0.080 to 0.240 in.) of clearance between battery positive cable terminal rubber insulator and metal housing of starter motor solenoid.

2. After battery positive cable terminal is adjusted, using the feeler gauge, verify that the clearance is not less than 2 mm (0.080 in.). If out of specification, repeat the "II. ADJUSTING BATTERY POSITIVE TERMINAL AT STARTER MOTOR" procedure.

Note:
If clearance is greater than 6 mm (0.240 in.), cable interference to splash shield may result.

3. Install starter motor splash shield and retainer (PN14039420).

4. Lower vehicle on hoist.

5. Connect battery negative cable.

Torque: 17 N-m (151 in.lbs.)

6. Affix the campaign completion label as outlined in "CAMPAIGN COMPLETION LABEL."