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DENSO R5 Starter
Installation Guide For:
• 2002 Freightliner Columbia
• Detroit Diesel Series 60 Engine
DENSO R5 Starter Installation Guide 1 / 29
LA990009-1943
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This guide will assist the technician with the installation of the R5 starter on this particular application. These installation procedures may vary based on the engine and make, model & year of the vehicle. Prior to component replacement carefully troubleshoot the starting circuit to identify the true cause of failure. All replaced cables or wiring should match original (OEM) specifications AND when reinstalling bolts and hardware, torque to original specifications. DENSO R5 Starter Installatio
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Starter Preparation Read all installation instructions & service information carefully before installing the R5 starter. Installation Instructions Service Information Caution Tag These items are included with the starter. DENSO R5 Starter Installation Guide 3 / 29
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Starter Preparation Confirm the correct part number for the particular application. Visually inspect starter at these critical points. Proceed to vehicle preparation. DENSO R5 Starter Installation Guide 4 / 29
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Vehicle Preparation Locate the vehicle battery compartment and remove the battery cover. Disconnect and isolate the negative (-) battery cable from the negative (-) battery terminal. DENSO R5 Starter Installation Guide 5 / 29
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Vehicle Preparation Remove the wheel well protector on the driver side of the vehicle. Retain all mounting hardware. Proceed to starter removal. DENSO R5 Starter Installation Guide 6 / 29
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Starter Removal Before disconnecting cables from the original starter, identify and note location for reassembly. • Disconnect & remove all cables from the starter • Temporarily group all positive (+) cables together. • Temporarily group all negative (-) cables together. Remove the original starter from the vehicle. Save the original mounting hardware for the DENSO R5 starter installation. Proceed to inspection. DENSO R5 Starter Installation Guide 7 / 29
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Inspection Inspect the ring gear for burred or damaged teeth. Rotate the flywheel and observe the condition of the entire ring gear. Replace any ring gear with damaged or worn teeth. DENSO R5 Starter Installation Guide 8 / 29
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Inspection Check the condition of all battery cables. If out of specification, clean cable connectors or replace cables. Proceed to starter installation. DENSO R5 Starter Installation Guide 9 / 29
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Starter Installation Temporarily support the R5 starter and secure with the original 3 mounting bolts. • Ensure the drain tube is in the downward position Viewed from bottom of vehicle looking up Viewed from bottom of vehicle looking up DENSO R5 Starter Installation Guide 10 / 29
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Starter Installation NOTE: Starter shown from side view with drain tube in the downward position. Viewed from side of vehicle Torque the mounting bolts to the specifications indicated in the Series 60 service manual. Viewed from side of vehicle DENSO R5 Starter Installation Guide 11 / 29
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Starter Installation Check for minimum clearances of starter to: 1. Engine Block - 4mm (.16 inches) 2. Frame Rail - 25mm (1 inch) 3. Heat Source - 30mm (1.2 inches) (e.g. exhaust manifold) Proceed to wiring assembly. DENSO R5 Starter Installation Guide 12 / 29
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Wiring Assembly Starting Motor Overcrank Protection (OCP) Circuit Bypass (if equipped) The OCP circuit is an option used on many trucks. It utilizes a thermal switch to open the starter relay ground circuit when excessive starter temperatures are reached due to prolonged cranking of the starter motor. This is commonly called over-cranking. The information below describes the procedure to bypass the OCP circuit when replacing an OCP equipped starter with a DENSO R5 starter. The presence of OCP ca
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Wiring Assembly (if equipped with over-crank protection) Location of over-crank protection terminal in original starter. Jumper plug installed in original wire harness. DENSO R5 Starter Installation Guide 14 / 29
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Wiring Assembly (if equipped with over-crank protection) Tie off the OCP terminal and jumper plug to the main wire harness to prevent separation due to vibration. DENSO R5 Starter Installation Guide 15 / 29
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Wiring Assembly Remove the ties (adjacent to the engine) holding the positive (+) alternator cable in place. Loosen the cable bracket holding the alternator cable to the engine block. DENSO R5 Starter Installation Guide 16 / 29
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Wiring Assembly Carefully maneuver the alternator cable through the cable bracket, toward the starter, to allow sufficient length for proper connection to the B+ (30) terminal. Re-align the cable bracket to the original position and torque to specifications. DENSO R5 Starter Installation Guide 17 / 29
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Wiring Assembly B+ Battery Cable Cab Mount Bracket Starter Mounting Loosen the B+ battery cable bracket Bolt located under the cab. Carefully maneuver the positive (+) battery cable, toward the starter, to allow sufficient length for proper connection to the B+ (30) terminal. DENSO R5 Starter Installation Guide 18 / 29
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Wiring Assembly Re-secure the B+ battery cable bracket located under the cab. Remove the temporary tie securing the positive (+) cables and wiring. DENSO R5 Starter Installation Guide 19 / 29
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Wiring Assembly Extend the key switch wire and relay circuit within the wiring harness protector approximately 1 inch. Connect the key switch wire to the 50 terminal and secure with retaining nut. Tighten and torque to: 2.6-4.6 Nm, 27-48 kgf.cm, 1.5-2.2 lbt.ft. Do not over-tighten terminal retaining nut. DENSO R5 Starter Installation Guide 20 / 29
