Denso R5 User manual

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DENSO R5 Starter Installation Guide
LA990009-1943
DENSO R5 Starter
Installation Guide For:
• 2002 Freightliner Columbia
• Detroit Diesel Series 60 Engine

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DENSO R5 Starter Installation Guide
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.

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DENSO R5 Starter Installation Guide
Read all installation instructions & service information carefully before
installing the R5 starter.
These items are included with the starter.
Starter Preparation
Installation Instructions Service Information Caution Tag

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DENSO R5 Starter Installation Guide
Confirm the correct part number for
the particular application.
Starter Preparation
Visually inspect starter at these
critical points.
Proceed to vehicle preparation.

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DENSO R5 Starter Installation Guide
Locate the vehicle battery
compartment and remove the battery
cover.
Vehicle Preparation
Disconnect and isolate the negative
(-) battery cable from the negative (-)
battery terminal.

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DENSO R5 Starter Installation Guide
Remove the wheel well protector on
the driver side of the vehicle. Retain
all mounting hardware.
Vehicle Preparation
Proceed to starter removal.

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DENSO R5 Starter Installation Guide
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.
Starter Removal
Remove the original starter from
the vehicle.
Save the original mounting
hardware for the DENSO R5
starter installation.
Proceed to inspection.

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DENSO R5 Starter Installation Guide
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.
Inspection

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DENSO R5 Starter Installation Guide
Check the condition of all battery
cables. If out of specification, clean
cable connectors or replace cables.
Inspection
Proceed to starter installation.

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DENSO R5 Starter Installation Guide
Viewed from bottom of vehicle looking up
Temporarily support the R5 starter
and secure with the original 3
mounting bolts.
• Ensure the drain tube is in the
downward position
Starter Installation
Viewed from bottom of vehicle looking up