Starting System Cadillac Catera I

STARTER IDENTIFICATION

STARTER IDENTIFICATION

DESCRIPTION & OPERATION

All models are equipped with Delco-Remy starters. When the ignition switch is turned to the START position, the Delco-Remy 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. (Scheme 1)

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.

Starters with the PG designation have a pinion that is driven by a gear reduction system. These starters are easily identified by 3 Torx bolts that retain the solenoid and should not be dissembled for any reason. They are serviceable only by complete replacement.

Scheme 1

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TRANSMISSION RANGE SWITCH

Place transmission shift lever in neutral position. Raise and support vehicle. Remove switch cover and wire harness connector from bracket. Remove transmission gear selector shaft nut and slide selector shaft lever from shaft. Loosen transmission range switch bolts. Connect ohmmeter to terminals "E" and "H". Rotate switch to determine range of contact (about 5 degrees). Position switch in center of contact range. Tighten transmission range switch bolts.

TROUBLE SHOOTING

Note. For information not covered in this article, see the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL INFORMATION section.

TROUBLE SHOOTING HINTS

On all models, note condition of SECURITY indicator light. If indicator stays on or flashes continuously, see ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. Check starter solenoid terminals and battery grounds. Check for proper installation of aftermarket electronic equipment. Perform self-diagnostic system test, to be certain no trouble codes are stored in PCM memory which may lead to misdiagnosis. See TESTS W/CODES article in ENGINE PERFORMANCE.

Check 80-amp V2 fuse, located in power distribution fuse block. See COMPONENT LOCATIONS table. If fuse is open, check for a short to ground in Red wire between power distribution fuse block connector terminal "X" and ignition switch connector terminal "Y". Ensure battery voltage exists at voltage side of 80-amp V2 fuse. If battery voltage does not exist, check for open in Red wire between power distribution fuse block connector terminal No. 1 and battery positive terminal.

STARTER NOISE

Note. 3.0L engines can not be shimmed. Noise condition, requiring shims, can only be corrected by replacing starter.

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 In (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" exists 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. On 3.0L engines, ensure starter-to-engine bolts are tightened correctly. Refer to the «TORQUE SPECIFICATIONS»(/cadillac/catera/i-1996-2001/remont/starter/#starting-system). 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. If using.039 In (1.0 mm) double shims, do not install more then 2 shims. If using.015 In (.38 mm) double shims, do not install more then 3 shims. If condition is not corrected, and pinion-to-flywheel clearance has been reached, single shims may be added to outer side of starter motor bolt using.015 In (.38 mm) shims. See STARTER under «REMOVAL & INSTALLATION»(/cadillac/catera/i-1996-2001/remont/starter/#starting-system__removal-installation).

Scheme 2

ON-VEHICLE TESTING

Note. The following tests assume that engine and battery are operating normally and are at operating temperature, battery is charged, there are no engine problems that would cause a no-start condition, and no diagnostic trouble codes are present.

SLOW OR NO CRANK AFTER EXTENDED PERIODS OF VEHICLE NON-USE

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

ENGINE DOES NOT CRANK, SOLENOID CLICKS

1. Place gear selector in Park. Disconnect starter solenoid terminal C2 (Black/Red wire) turn ignition switch to START position and hold. Using a DVOM, measure voltage between starter solenoid terminal C2 (Black/Red wire) and ground. If voltage is 9.5 volts or less, go to next step. If voltage is more than 9.5 volts, repair or replace starter solenoid and recheck symptom.
2. Turn ignition switch to START position and hold. Measure voltage between ignition switch connector terminal "Z" and ground. If battery voltage does not exist, go to next step. If battery voltage exists, repair open or high resistance in Black/Red wire between starter solenoid terminal C2 ("S") and transmission range switch connector terminal "E", and in Black/Red wire between transmission range switch connector terminal "H" and ignition switch connector terminal "Z". If Black/Red wires are okay, adjust or replace transmission range switch and recheck symptom.
3. Using a DVOM, measure voltage between ignition switch connector terminal "Y" (Red wire) and ground. If battery voltage exists, replace ignition switch and recheck symptom. If battery voltage does not exist, repair open or high resistance in Red wire between ignition switch connector terminal "Y" and power distribution fuse block connector terminal "X" and recheck symptom.

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.

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 the «HOLD-IN WINDINGS SPECIFICATIONS»(/cadillac/catera/i-1996-2001/remont/starter/#starting-system) table. Check ammeter reading. Turn off carbon pile and open switch. See the «HOLD-IN WINDINGS SPECIFICATIONS»(/cadillac/catera/i-1996-2001/remont/starter/#starting-system) table. If amperage reading is not as specified, 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 the PULL-IN WINDINGS SPECIFICATIONS table. Check ammeter reading. Turn off carbon pile and open switch. Refer to the PULL-IN WINDINGS SPECIFICATIONS table. If ammeter reading is not as specified, replace starter solenoid.

HOLD-IN WINDINGS SPECIFICATIONS

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»(/cadillac/catera/i-1996-2001/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 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, bent armature shaft, 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. If starter vibrates or is noisy, armature may be rubbing against inside of frame and field.

Scheme 4

STARTER NO-LOAD TEST SPECIFICATIONS

ARMATURE TEST

Note. Any ball bearings that are removed from armature must be replaced witch new bearings.

1. Inspect solder joints between armature windings and commutator bars. If any have come loose, replace armature. Replace armature assembly if commutator outer diameter is less than 1.378 in (36 mm) or if undercut depth is less than .008 in (.2 mm). Replace armature assembly if commutator outer diameter is less than 1.228 in (31.2 mm). DO NOT undercut insulation. 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

If any brushes are damaged (oil-soaked or pitted) or worn more than 90 percent, replace the frame and fields. Refer to the MINIMUM BRUSH LENGTH table. If brushes are not damaged and still have more than 50 percent, use a soft cloth to clean contact face of brushes. 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.

MINIMUM BRUSH LENGTH

COMMUTATOR END FRAME & BEARING

Ensure commutator end bearing has not spun in frame. If bearing has spun, replace frame and bearing. DO NOT lubricate bearing. If bearing is dry or damaged, replace bearing. Measure original bearing depth and install new bearing to same depth.

DRIVE END HOUSING & BEARING

Ensure drive end bearing has not spun in housing. If bearing has spun, replace housing and bearing. DO NOT lubricate bearing. If bearing is dry or damaged, replace bearing. Measure original bearing depth and install new bearing to same depth.

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

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

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. (Scheme 7)
2. Push pinion as far as possible away from retainer. Using a feeler gauge, ensure there is.010-.160 in (.25-4.06 mm) clearance between pinion and retainer. (Scheme 8)

Scheme 7

Scheme 8

REMOVAL & INSTALLATION

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.

Note. On 3.0L engines, starters cannot be shimmed. Noise condition, requiring shims, can only be corrected by replacing starter.

Removal

Disconnect negative battery cable. Raise and support vehicle. Remove electrical leads from starter motor. Remove passenger side catalytic converter. Remove passenger side engine mount nuts. Lower vehicle and remove air cleaner housing to throttle body ducts. Raise and support passenger of engine to approximately 1.5 in (38 mm). Raise vehicle. Remove engine mount from engine bracket and cradle. Remove engine mount bracket bolts and reposition bracket. Remove starter bolts and starter.

Installation

Install starter. Install engine mount to bracket and cradle. Partially lower vehicle. Have assistant guide engine mount into place while lowering engine. Engine mount locator tab must engage slot in cradle. (Scheme 9) To complete installation, reverse removal procedure. Tighten starter mounting bolts to specification. See the TORQUE SPECIFICATIONS.

Scheme 9

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• ANTI-THEFT SYSTEMS
• TESTS W/CODES
• AIR BAG RESTRAINT SYSTEM
• PARASITIC LOAD EXPLANATION & TEST PROCEDURES
• COMPUTER RELEARN PROCEDURES
• COMPONENT LOCATIONS
• REMOVAL & INSTALLATION