Starting System Buick Riviera VIII

DESCRIPTION

The Delco-Remy starter is part of the cranking circuit, which also consists of the battery, ignition switch and related wiring. (Scheme 1) When the ignition switch is turned to the START position, the starter solenoid windings are energized. This causes the solenoid plunger to move the shift lever, which engages the pinion with the engine flywheel ring gear. The movement of the plunger also closes the main solenoid contacts, applying battery voltage to the starter motor.

When the engine starts, the pinion will overrun, protecting the armature from excessive speed and the flywheel from damage. When the ignition switch is released, the plunger return spring disengages the pinion.

On starters with the SD designation, the pinion is driven directly by the armature shaft. Wound field coils energize pole pieces that are arranged around the armature. These are used on gasoline engines. Starters designated with PG have a pinion that is driven by a gear reduction system. These starters are used on diesel or large displacement gasoline engines. The PG260 starter should not be dissembled for any reason and is serviceable only by complete replacement.

Scheme 1

STARTER NOISE

1. A high-pitched whine, heard while cranking (before engine starts), indicates excessive distance between starter pinion and flywheel. If high-pitched whine is heard after engine starts and key is released, distance between starter pinion and flywheel is too small. Pinion-to-flywheel clearance should be.020" (0.5 mm). (Scheme 2)
2. If loud, siren-like "whoop" sound is heard after the engine starts, drive assembly is likely defective. If "rumble", "growl" or "knock" is present as starter is coasting to a stop after starting engine, starter armature is bent or unbalanced. NOTE: Check flywheel ring gear for damage.
3. If diagnosis indicates pinion should be closer to flywheel, ensure proper starter motor was installed. During initial starter motor installation, shim(s) are not used. If shim(s) are present, remove as necessary.
4. If diagnosis indicates pinion should be moved away from flywheel, add one shim. Consult manufacturer for required shim size. If condition is not corrected, another shim may be added. See «STARTER»(/buick/riviera/viii-1994-1999/remont/starter/#starting-system) under REMOVAL & INSTALLATION.

Scheme 2

Note. For additional trouble shooting information, refer to the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

CRANKING TEST

Note. The following tests assume that engine and battery are operating normally and that there are no engine problems that would cause a no-start condition.

Note. Anti-Theft and PASS-Key II systems interact with cranking system through a starter enable relay or theft deterrent relay. On models with Anti-Theft system and/or PASS-Key II system, ensure both systems and related controls are operating properly. See ANTI-THEFT SYSTEM article in ACCESSORIES & EQUIPMENT. On models with Anti-Theft system, an unauthorized entry will cancel starter enable operation. On all models, ensure no diagnostic trouble codes are present.

Slow Or No Crank Only After Extended Periods Of

Vehicle Non-Use

There may be a parasitic load on electrical system. See PARASITIC LOAD EXPLANATION & TEST PROCEDURES article in GENERAL INFORMATION.

Engine Does Not Crank, Starter Solenoid Does Not Click ("A" Body Cars)

1. Place gear selector in Park. Turn ignition switch to START position. Using DVOM, measure voltage between starter solenoid terminal "S" (Purple wire) and ground. (Scheme 2) See «WIRING DIAGRAM»(/buick/riviera/viii-1994-1999/remont/starter/#starting-system). If voltage is greater than 9.5 volts, go to next step. If voltage is less than 9.5 volts, go to step 3).
2. Connect a remote starter switch between starter solenoid terminal "S" (Purple wire) and battery positive terminal. If starter cranks, using remote starter switch, check for high resistance or poor connection between ignition switch and starter solenoid. If starter does not crank, replace starter solenoid.
3. Disconnect transaxle range switch. Turn ignition switch to START position. Using DVOM, measure voltage between transaxle range switch ignition terminal (Yellow wire) and ground. If voltage is less than 9.5 volts, go to next step. If voltage is greater than 9.5 volts, check Purple wire circuit between transaxle range switch and starter solenoid terminal "S" for an open or high resistance. If circuit is okay, adjust or replace transaxle range switch.
4. Locate Black 48-pin connector behind left side of instrument panel, below steering column. Using DVOM, backprobe 48-pin connector terminal D5 (Red wire) to ground and measure voltage. If voltage is greater than 9.5 volts, check Yellow wire between ignition switch and transaxle range switch for an open circuit or high resistance, or check Black 48-pin connector for a poor connection. If Yellow wire and connection are okay, replace ignition switch.
5. If voltage is less than 9.5 volts, check Red wire between Black 48-pin connector terminal D5 and battery for an open circuit. If Red wire is okay, replace fusible link "C", located in left front corner of engine compartment, near battery.

Engine Does Not Crank, Starter Solenoid Does Not Click

1. Place gear selector in Park. Turn ignition switch to START position and observe SECURITY indicator on instrument cluster. SECURITY indicator should illuminate for 5 seconds then go out.
2. If SECURITY indicator does not remain illuminated or does not flash continuously, go to next step. If SECURITY indicator remains illuminated or flashes continuously, problem exists within anti-theft system. See «ANTI-THEFT SYSTEM»(/buick/riviera/viii-1994-1999/remont/door-locks-anti-theft-systems/#anti-theft-system) article in ACCESSORIES & EQUIPMENT.
3. Load test battery. Replace battery if it fails load test. Check battery cables and battery cable connections. If battery cables and connections are okay, go to next step. If battery cables and connections are faulty, repair or replace battery cables and connections as necessary.
4. Remove 15-amp INJ fuse (Riviera), or 10-amp INJ 1 and 10-amp INJ 2 fuses (Aurora), located in instrument panel fuse block, to prevent engine from starting. Turn ignition switch to START position. Using DVOM, measure voltage between starter solenoid terminal "S" (Purple wire) and ground. (Scheme 2) See WIRING DIAGRAM. If voltage is less than 8 volts, go to next step. If voltage is 8 volts or greater, check for starter solenoid terminal "S" for poor connections. Also, check for poor or dirty ground between starter and engine block. If connections and ground are okay, repair or replace starter assembly.
5. Turn ignition switch to START position. Locate Black 78-pin C101 connector in engine compartment on center of firewall. Using DVOM, backprobe Black 78-pin C101 connector terminal G7 (Purple wire). Disconnect Purple wire from starter solenoid terminal "S". Measure voltage from female side of Black 78-pin C101 connector terminal G7 (Purple wire) and ground. If voltage is less than 8 volts, go to next step. If voltage is 8 volts or greater, check Black 78-pin C101 connector terminals for poor connections. Also, check for open circuit in Purple wire between starter solenoid terminal "S" and starter enable relay. If connections and Purple wire are okay, replace starter solenoid.
6. Locate Black 30-pin C102 connector in engine compartment on center of firewall. Using DVOM, backprobe Black 30-pin C102 connector terminal A2 (Purple wire). Measure voltage from female side of Black 30-pin C102 connector terminal A2 (Purple wire) and ground. If voltage is less than 8 volts, go to next step. If voltage is 8 volts or greater, check Black 30-pin C102 connector terminals for poor connections. Also, check for open circuit or short to ground in Purple wire circuit between starter solenoid terminal "S" and starter enable relay. Repair as necessary.
7. Reconnect Purple wire to starter solenoid terminal "S". Disconnect park/neutral position switch connector C1 located on left center of engine, on transaxle. Connect test light between park/neutral position switch connector C1 terminal "G" (Yellow wire) and ground. Turn ignition switch to START position. If test light does not illuminate, go to next step. If test light illuminates, check anti-theft system for proper operation. Also, check for open circuit in Yellow/Black wire between park/neutral position switch and Pass-Key II decoder module, and park/neutral position switch connector terminals for poor contact or damage. Repair as necessary.
8. Reconnect park/neutral position switch connector C1. Remove 10-amp CRANK fuse, located in instrument panel fuse block. Connect test light between 10-amp CRANK fuse connector terminal C14 (Yellow wire) and ground. Turn ignition switch to START position. If test light does not illuminate, go to next step. If test light illuminates, check for open circuit in Purple wire between CRANK fuse and starter enable relay, and in Yellow wire between starter enable relay and park/neutral position switch. Also, check for open circuit or high resistance between starter enable relay terminals C1 (Yellow wire) and A2 (Purple wire).
9. Locate Natural 48-pin C202 connector behind dash, at base of steering column. Using DVOM, backprobe Natural 48-pin C202 connector terminal D5 (Red wire). Measure voltage between Natural 48-pin C202 connector terminal D5 (Red wire) and ground. If voltage is 8 volts or greater, go to next step. If voltage is less than 8 volts, check for open circuit or short to ground in Red wire between ignition switch and battery booster positive cable. If necessary, replace 60-amp IGN 3 fuse, located in rear maxi fuse block No. 2 under left side of rear seat.
10. Turn ignition switch to START position and hold. Using DVOM, backprobe Natural 48-pin C202 connector terminal B6 (Yellow wire). Measure voltage between Natural 48-pin C202 connector terminal B6 (Yellow wire) and ground. If voltage is less than 8 volts, go to next step. If voltage is 8 volts or greater, check for open circuit in Yellow wire between ignition switch, 10-amp CRANK fuse and starter enable relay, and in Purple wire between starter enable relay and starter solenoid terminal "S". Also, check starter enable relay. Repair or replace as necessary.
11. Check Natural 48-pin C202 connector for poor terminal contact. Check for open or short to ground in Yellow wire circuit between ignition switch, 10-amp CRANK fuse and starter enable relay. Check ignition switch for damage. Check for open circuit in Red wire between ignition switch and battery booster positive cable. Also, check for open circuit in steering column wiring harness. Repair or replace as necessary.

Solenoid Clicks, Engine Does Not Crank

1. Ensure battery is fully charged. Remove 15-amp INJ fuse (Riviera), or 10-amp INJ 1 and 10-amp INJ 2 fuses (Aurora) located in instrument panel fuse block to prevent engine from starting.
2. Using DVOM, measure voltage between battery positive terminal and battery negative terminal while cranking engine for at least 15 seconds. If voltage is greater than 9.5 volts, go to step 5). If voltage is less than 9.5 volts, go to next step.
3. Load test battery. If load test is okay, check battery and starter terminals for corrosion or poor connections. If terminals are okay, repair or replace starter solenoid. If load test is not okay, replace battery.
4. Locate battery negative terminal ground. Using DVOM, measure voltage between battery negative terminal and battery negative terminal ground connection while cranking engine for at least 15 seconds. If voltage is less than 0.5 volt, go to next step. If voltage is greater than 0.5 volt, clean connections and retest. If voltage is still not less than 0.5 volt, replace battery negative cable.
5. Using DVOM, measure voltage between battery positive terminal and starter solenoid terminal "B" while cranking engine for at least 15 seconds. If voltage is less than 0.5 volt, repair or replace starter solenoid. If voltage is greater than 0.5 volt, clean connections and retest. If voltage is still not less than 0.5 volt, replace battery positive cable.

PRELIMINARY TESTS

Remove starter from vehicle. See STARTER under REMOVAL & INSTALLATION. Check starter for damage such as broken or stripped electrical terminals, broken or cracked drive end housing, etc. If no obvious damage is found, perform starter no-load test and pinion clearance check before disassembling starter motor.

Note. On PG260 and PG260M starter motors, starter is serviced as an assembly. If test values do not meet specifications, replace starter and solenoid as an assembly.

SOLENOID WINDINGS TESTS

Note. To prevent overheating, DO NOT allow solenoid pull-in current to flow for more than 15 seconds.

Note. Current flow will decrease as windings heat up.

Hold-In Windings Test

1. If solenoid is not removed from starter motor assembly, disconnect field lead from terminal "M" on solenoid and insulate field lead from solenoid motor terminal. Connect an ammeter and switch in series with 12-volt battery and starter solenoid terminal "S" as illustrated. (Scheme 3) Connect a voltmeter between solenoid terminal "S" and ground. Connect a carbon pile across battery.
2. Turn switch on and quickly adjust carbon pile load until voltage reads as specified. See PULL-IN WINDINGS SPECIFICATIONS table. Check ammeter reading. Turn off carbon pile and open switch. If amperage reading is not 5-15 amps, replace starter solenoid.

Pull-In Windings Test

Connect test equipment as in hold-in windings test. See HOLD-IN WINDINGS TEST. (Scheme 3) Ground starter solenoid terminal "M". Turn switch on and quickly adjust carbon pile load until voltage reads as specified. See PULL-IN WINDINGS SPECIFICATIONS table. Check ammeter reading. Turn off carbon pile and open switch. See PULL-IN WINDINGS SPECIFICATIONS table. If ammeter reading is not as specified, replace starter solenoid.

PULL-IN WINDINGS SPECIFICATIONS

Scheme 3

STARTER NO-LOAD TEST

1. Secure starter in vise. Turn carbon pile off and open switch. Connect test equipment to starter as illustrated. (Scheme 4) Turn switch on and adjust carbon pile until voltage reads as specified. See «STARTER NO-LOAD TEST SPECIFICATIONS»(/buick/riviera/viii-1994-1999/remont/starter/#starting-system) table. Check ammeter reading and pinion speed on RPM indicator. Turn off carbon pile and open switch. Compare RPM and amperage readings with specifications. See «STARTER NO-LOAD TEST SPECIFICATIONS»(/buick/riviera/viii-1994-1999/remont/starter/#starting-system) table. CAUTION: DO NOT apply more voltage than specified. Excessive voltage may cause armature to throw windings due to excessive speed.
2. If amperage and RPM readings are as specified, starter motor is okay. If test indicates low free speed and/or high current draw, unit may have tight, dirty or worn bearings or bushings, shorted or grounded armature, or a grounded field.
3. High current draw with pinion moving into cranking position but no pinion rotation indicates a direct ground in field, or frozen bearings or bushings. No pinion movement and a normal current reading indicates plunger is unable to move into solenoid or drive is unable to move on armature shaft. No pinion movement and very low or no current draw indicates an open or ground in solenoid windings.
4. Pinion moving into cranking position but not turning and very low current draw indicates an open in field circuit or armature windings, or no current flow between solenoid battery and motor field terminals while motor is engaged. Connect a jumper wire between solenoid battery and motor field terminal "M". If motor now turns at specified RPM, replace solenoid.
5. Low no-load and low current draw indicates high internal resistance due to poor brush lead connections; a dirty commutator; an open in armature windings; broken, worn or weak brush springs; or worn, damaged or dirty brushes. High no-load speed and high current draw indicates shorted field coils or shorted armature windings.

Scheme 4

STARTER NO-LOAD TEST SPECIFICATIONS

ARMATURE TEST

1. Inspect solder joints between armature windings and commutator bars. If any have come loose, replace armature. If commutator is rough or damaged, replace armature. DO NOT turn commutator in lathe or undercut spaces between bars. If commutator is dirty, clean with 400 grit emery cloth and blow away any copper dust.
2. Using growler, check armature for shorts. Hold a flat steel strip on armature parallel to armature core or shaft. Rotate armature in growler. Steel strip will vibrate on area of short circuit.
3. Using self-powered test light, place one lead on armature shaft and other lead on commutator. Test light should not illuminate. If test light illuminates, armature is shorted or grounded and must be replaced.
4. If no-load test indicated armature may be rubbing against inside of frame and field assembly, inspect outside of armature for signs of rubbing. If armature is scored only on one side of laminations, armature shaft may be bent and armature should be replaced. If scoring is all around armature laminations, check frame and field assembly for an out-of-position pole or for a foreign object lodged inside. Repair or replace frame and field assembly.

FIELD COIL OPEN TEST

Remove armature from frame and field assembly. Using self-powered test light, place one lead on field lead connection and other lead on one insulated brush. (Scheme 5) Test light should illuminate. If test light does not illuminate, field coil is open. Repair or replace field and frame assembly. Repeat test for each insulated brush.

Scheme 5

FIELD COIL GROUND TEST

Remove armature from field and frame assembly. On starters with shunt lead, separate field and shunt lead connections during test. Ensure field lead connection is NOT touching ground during test. Using self-powered test light, place one lead on grounded brush holder and other lead on one insulated brush. (Scheme 6) Test light should not illuminate. If test light illuminates, field coil is grounded. Repair or replace field and frame assembly. Repeat test for each insulated brush.

Scheme 6

BRUSHES, SPRINGS & HOLDERS CHECK

Replace brushes if worn to 1/2 of original length, oil-soaked or pitted. Check brush spring tension and replace springs if weak, discolored or distorted. Ensure brush holders are clean and brushes are not binding in holders. Ensure full surface of brush contacts commutator for proper performance.

DRIVE ASSEMBLY CHECK

1. Check pinion teeth for chips, cracks or excessive wear. If pinion teeth are damaged, replace drive assembly. Also check flywheel for damage. Check drive assembly for slipping before disassembly from armature. With drive assembly attached to armature, cover armature with shop towels and secure in a vise.
2. Using a 12-point socket and a torque wrench, turn pinion counterclockwise. Pinion should lock and withstand a torque of 50 ft. lbs. (68 N.m) without slipping. If pinion slips before 50 ft. lbs. (68 N.m) is reached, replace drive assembly.
3. Using a 12-point socket and a torque wrench, turn pinion clockwise. Pinion should turn freely in overrunning direction (clockwise) only. If pinion does not turn freely in clockwise direction, replace drive assembly.

PINION CLEARANCE CHECK

1. Secure starter motor in vise with opening in housing accessible for measurement. Disconnect field lead at solenoid terminal "M" and insulate from solenoid field terminal "M". Connect battery negative terminal lead to starter frame. Connect 12 volts to starter solenoid terminal "S". Momentarily touch jumper lead from starter solenoid terminal "M" to starter frame, shifting pinion into cranking position.
2. Push pinion as far as possible away from retainer. Using a feeler gauge, ensure there is.010-.160" (.25-4.06 mm) clearance between pinion and retainer. (Scheme 7)

Note. Pinion clearance is not adjustable. If clearance is not within specification, disassemble and check starter motor for worn or damaged components.

Scheme 7

REMOVAL & INSTALLATION

STARTER

Note. Vehicles are designed for starter mounting without shims. A single shim or double shims may have been added to correct a noise or engagement condition. When installing starter any previously installed shims should be replaced in original location to ensure proper pinion to flywheel clearance.

Removal (3.8L)

1. Disconnect negative battery cable. Raise and support vehicle. As required, remove nuts from A/C compressor, exhaust system and/or engine braces, adjacent to starter. On M/T models, remove bending brace from around starter (if equipped). On all models, remove other items that may interfere with removal of starter.
2. If necessary, remove nut from engine cross brace. Using pry bar between upper engine mount and engine, pry rearward and support engine.
3. If necessary, remove oil filter, air induction tube and cooling fan. Remove flywheel inspection cover (if equipped). Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. Remove starter mounting bolts. Remove shims and note arrangement for reassembly. Remove starter.

Installation

Before installing starter onto engine, tighten inner solenoid terminal nuts to ensure they are secure in cap. Starter failure may occur due to terminal or cap damage. Install starter and wiring. Ensure shims are installed in original location. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS .

Removal (4.0L)

1. Disconnect negative battery cable, then positive battery cable. Remove intake manifold cover. Loosen fuel filler cap to relieve tank vapor pressure. Connect fuel pressure gauge (J-34730-1) to fuel pressure connection. Place fuel pressure gauge bleed hose in a container and open gauge bleed valve to relieve fuel system pressure.
2. Disconnect Intake Air Temperature (IAT) sensor electrical connector. Disconnect crankcase vent pipe at air intake duct. Remove air intake duct and air cleaner housing. Disconnect transaxle vent hose and vacuum lines at Idle Speed Control (ISC) actuator bracket. Disconnect vacuum manifold at throttle body. Disconnect Throttle Position (TP) sensor and ISC actuator electrical connectors. Disconnect cruise control servo vacuum hoses and electrical connector. Disconnect cruise control cable at throttle body. Remove cruise control servo and bracket.
3. Disconnect accelerator cable at throttle body and ISC actuator bracket. Disconnect front bank spark plug wires and position aside. Disconnect throttle body coolant hoses at throttle body and surge tank pipe. Disconnect Exhaust Gas Recirculation (EGR) pipe at throttle body spacer. Disconnect brake booster vacuum hose at intake manifold vacuum fitting. Disconnect fuel rail ground wire at rear cylinder head.
4. Disconnect quick-connect fittings at fuel rail. Remove fuel rail bracket at EGR valve. Disconnect Positive Crankcase Ventilation (PCV) hose at intake manifold. Disconnect injector harness main connector. Remove 6 bolts and 4 studs securing intake manifold, and remove intake manifold.
5. Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. Remove starter mounting bolts. Remove shims and note arrangement for reassembly. Remove starter.

1. Before installing starter onto engine, tighten inner solenoid terminal nuts to ensure they are secure in cap. Starter failure may occur due to terminal or cap damage. Install starter and wiring. Ensure shims are installed in original location. Tighten starter mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/riviera/viii-1994-1999/remont/starter/#starting-system__torque-specifications) .
2. Install intake manifold with throttle body attached. Tighten 6 intake manifold bolts and 4 intake manifold studs to 89 INCH lbs. (10 N.m). To complete installation, reverse removal procedure.

Starter motors do not require lubrication, except during overhaul. Roll-type overrunning clutch requires no lubrication. Drive assembly, however, should be wiped clean and lubricated with silicon grease on shaft, underneath overrunning clutch assembly.

Note. On PG260 starter motor, starter and solenoid are not overhauled and are replaced as a complete assembly.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starter System Wiring Diagram (Aurora & Riviera). Scheme 8

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• ANTI-THEFT SYSTEM
• PARASITIC LOAD EXPLANATION & TEST PROCEDURES
• COMPUTER RELEARN PROCEDURES
• STARTER
• TORQUE SPECIFICATIONS