SOLENOID REPLACEMENT The starter solenoid (magnetic switch) is an integral part of the starter assembly.

1. Remove the starter from the van. Remove the heat insulator from the starter assembly, if equipped.
2. Disconnect the wire lead from the magnetic switch terminal.
3. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
4. To separate the starter housing from the magnetic switch assembly, remove the two screws and the starter housing with the pinion gear (1.6 kW), idler and clutch assembly.
TO INSTALL:
5. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and place the clutch assembly, idler gear, bearing and pinion gear (1.6 kW) in the starter housing.
6. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
7. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts. Tighten the bolts on the 1.4 kW to 52 inch lbs. (6 Nm) and on the 1.6 kW to 82 inch lbs. (9 Nm).
NOTE: There is a protrusion or tab on each part; make sure you line them up correctly during assembly.
8. Connect the wire to the terminal on the magnetic switch and tighten the nut to 52 inch lbs. (6 Nm). Install the heat insulator, if equipped.
9. Reinstall the starter on the vehicle. Check starter system for proper operation.

RELAY REPLACEMENT
(See Figure 52) The starter relay is located up under the dash on the driver side of the vehicle behind the cruise control actuator. Remove the actuator and extract the relay from the fuse block. Simply pull the relay out of the block.

LOWER BALL JOINT | INSPECTION
(See Figure 18)

1. Remove the ball joint from the lower control arm and place it into a vise.
2. Flip the ball joint stud back and forth 5 times before installing the nut.
3. Using a torque wrench, turn the nut continuously one turn every 2-4 seconds, and take the torque reading on the 5th turn. The turning torque should be 13-35 inch lbs. (2-4 Nm).
4. If the ball joint fails the testing, replace it.

REMOVAL AND INSTALLATION
(See Figures 19, 20, 21 and 22)

1. Raise and support the vehicle.
2. Remove the ball joint bolts connecting it to the steering knuckle.
3. Remove the cotter pin.
4. Loosen but do not remove the nut.
5. Using a puller, separate the ball joint from the control arm.