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Starting System Chevrolet Chevy Express H2500

Starter 10 illustrations ~3909 words

FASTENER TIGHTENING SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Battery Negative Cable-To-Battery13 (17)
Starter Bolts
4.3L33 (45)
4.8L, 5.3L & 6.0L37 (50)
INCH Lbs. (N.m)
Right Transmission Cover Bolt80 (9)
Starter Positive Lead Nut89 (10)
Starter Solenoid Nut
4.3L18 (2)
4.8L, 5.3L & 6.0L30 (3.4)

FASTENER TIGHTENING SPECIFICATIONS

STARTER MOTOR USAGE

ApplicationStarter Type
4.3L (LU3), 4.8L (LR4) & 5.3L (LM7)PG-260G
6.0L (LQ4)PG-260L

STARTER MOTOR USAGE

SCHEMATIC & ROUTING DIAGRAMS

For 2003 wiring diagrams, refer to the following

  1. For Chevy Express G1500, see «STARTING/CHARGING»(ref-154376-S22277214202003080900000) in SYSTEM WIRING DIAGRAMS - G1500 article in ELECTRICAL.
  2. For Chevy Express G2500, see «STARTING/CHARGING»(ref-154377-S18304301122003080900000) in SYSTEM WIRING DIAGRAMS - G2500 article in ELECTRICAL.
  3. For Chevy Express G3500, see «STARTING/CHARGING»(ref-154378-S08788021092003080900000) in SYSTEM WIRING DIAGRAMS - G3500 article in ELECTRICAL.
  4. For Chevy Express H1500, see «STARTING/CHARGING»(ref-154379-S42087871762003080900000) in SYSTEM WIRING DIAGRAMS - H1500 article in ELECTRICAL.
  5. For Chevy Express H2500, see «STARTING/CHARGING»(ref-154380-S34198408692003080900000) in SYSTEM WIRING DIAGRAMS - H2500 article in ELECTRICAL.
  6. For Savana G1500, see «STARTING/CHARGING»(ref-154351-S32914206852003080900000) in SYSTEM WIRING DIAGRAMS - G1500 article in ELECTRICAL.
  7. For Savana G2500, see «STARTING/CHARGING»(ref-154352-S33018722812003080900000) in SYSTEM WIRING DIAGRAMS - G2500 article in ELECTRICAL.
  8. For Savana G3500, see «STARTING/CHARGING»(ref-154353-S03194260662003080900000) in SYSTEM WIRING DIAGRAMS - G3500 article in ELECTRICAL.
  9. For Savana H1500, see «STARTING/CHARGING»(ref-154354-S14270807982003080900000) in SYSTEM WIRING DIAGRAMS - H1500 article in ELECTRICAL.
  10. For Savana H2500, see «STARTING/CHARGING»(ref-154355-S17158103102003080900000) in SYSTEM WIRING DIAGRAMS - H2500 article in ELECTRICAL.
  11. For Savana Camper Special, see «STARTING/CHARGING»(ref-154356-S02304551442003080900000) in SYSTEM WIRING DIAGRAMS - G3500 article in ELECTRICAL.
  12. For Savana Special, see «STARTING/CHARGING»(ref-154357-S30689021312003080900000) in SYSTEM WIRING DIAGRAMS - G3500 article in ELECTRICAL.

COMPONENT LOCATOR

ComponentLocation
Powertrain Control Module (PCM)In Engine Compartment, Attached To Left Front Fender
Starter (1)Attached To Lower Right Rear Of Engine
STARTER RelayIn Underhood Fuse Block
(1) (Scheme 1)

COMPONENT LOCATOR

Scheme 1

Scheme 1: ENGINE ELECTRICAL COMPONENT VIEWS
Scheme 1: ENGINE ELECTRICAL COMPONENT VIEWS

DIAGNOSTIC STARTING POINT - ENGINE ELECTRICAL

Begin the system diagnosis with the DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL . The Diagnostic System Check will provide the following information

  1. The identification of the control module(s) which command the system.
  2. The ability of the control module(s) to communicate through the serial data circuit.
  3. The identification of any stored diagnostic trouble codes (DTCs) and their status.

The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located.

Test Description

The numbers below refer to the step numbers in the test procedure.

  1. 3 - Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition.
  2. 4 - The symptom list in will determine the correct diagnostic procedure to use.
  3. 5 - The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed.

Test Procedure

  1. Perform the Battery Inspection/Test. For 2003, see «BATTERY TESTING & INSPECTION»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__battery-testing-inspection) in CHARGING SYSTEM in ELECTRICAL. Does the battery pass the test? If yes, go to next step. If no, perform test again.
  2. Install a scan tool. Does the scan tool power up? If yes, go to next step. If no, go to BODY CONTROL MODULES article in COMMUNICATION DEVICES in ACCESSORIES & EQUIPMENT.
  3. Turn ON the ignition, with the engine OFF. Attempt to communicate with the powertrain control module (PCM) on the class 2 serial data circuit. Does the scan tool communicate with any module on the class 2 serial data circuit? If yes, go to next step. If no, go to BODY CONTROL MODULES article in COMMUNICATION DEVICES in ACCESSORIES & EQUIPMENT.
  4. Select the Display DTCs function for each module. If using a Tech 2, use the Class 2 DTC Check feature in order to determine which modules have DTCs set. Record all of the displayed DTCs the DTC status and the module which set the DTC. Does the scan tool display any DTCs? If yes, go to next step. If no, go to «SYMPTOMS - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__symptoms-engine-electrical) .
  5. Does the scan tool display any DTC beginning with "U"? If yes, go to BODY CONTROL MODULES article in COMMUNICATION DEVICES in ACCESSORIES & EQUIPMENT. If no, go to appropriate article, refer to the following: For 2003, see «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__diagnostic-trouble-code-definitions) under SELF-DIAGNOSTIC SYSTEM in GENERATORS & REGULATORS article.

SYMPTOMS - ENGINE ELECTRICAL

The following steps must be completed before using the symptom list.

  1. Perform «DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) before using the «SYMPTOM LIST»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__symptom-list) in order to verify that there are no DTCs set and that the control module(s) can communicate via the serial data link.
  2. Review the system operation in order to familiarize yourself with the system functions. See «DESCRIPTION & OPERATION»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) .

Visual/Physical Inspection

  1. Inspect for aftermarket devices which could affect the operation of the starting and charging systems.
  2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

Intermittents

Intermittent faulty electrical connections or wiring may be the cause of intermittent conditions. Check for loose, bent or corroded terminals and terminal tension. Check for cut, bare or pinched wiring. Simulate the condition that is potentially causing intermittent connection, either by wiggling the connections or the wiring, test driving or performing other operations while observing scan tool, DVOM or other testing equipment.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

  1. «STARTER SOLENOID DOES NOT CLICK»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-solenoid-does-not-click)
  2. «STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-solenoid-clicks-engine-does-not)
  3. «ENGINE CRANKS SLOWLY»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__engine-cranks-slowly)
  4. «STARTER MOTOR NOISE DIAGNOSIS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system)

STARTER SOLENOID DOES NOT CLICK

  1. Did you perform the Engine Electrical Diagnostic System Check? If yes, go to next step. If no, go to «DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) .
  2. Turn the ignition switch to the START position. Does the engine crank? If yes, go to «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. If no, go to next step.
  3. Turn the ignition switch to the START position. Does the starter motor relay click? If yes, go to step 11 . If no, go to next step.
  4. Is the vehicle equipped with a manual transmission? If yes, go to next step. If no, go to step 7 .
  5. Install a scan tool. Turn ON the ignition, with the engine OFF. With a scan tool, observe the Clutch Start Switch Signal parameter in the PCM data list while pressing the clutch pedal. Does the scan tool display Released/Applied? If yes, go to step 7 . If no, go to next step.
  6. Turn OFF the ignition. Disconnect the PCM harness connector. Connect a test lamp between the Clutch Start Switch Signal of the PCM harness and a good ground. Turn the ignition to the START position while pressing the clutch pedal. Does the test lamp illuminate? If yes, go to next step. If no, go to step 8 .
  7. Turn OFF the ignition. Disconnect the PCM harness connector. Connect a test lamp between the crank voltage circuit (starter enable relay control) of the PCM harness and a good ground. Turn the ignition to the START position. Does the test lamp illuminate? If yes, go to step 19 . If no, go to next step.
  8. Remove the starter motor relay. See «RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) under REPAIR INSTRUCTIONS. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to ground. With the transmission in park, or clutch pedal pressed, turn the ignition switch to the START position. Does the test light illuminate? If yes, go to next step. If no, go to step 10 .
  9. Connect a test light from the supply voltage circuit of the starter motor relay coil circuit to the control circuit of the starter motor relay coil circuit. With the transmission in park, or clutch pedal pressed, turn the ignition switch to the START position. Does the test light illuminate? If yes, go to step 17 . If no, go to step 14 .
  10. Turn OFF the ignition. Disconnect the park neutral position (PNP) switch. For 2003 4L60-E transmission, see «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e) under REMOVAL & INSTALLATION in SERVICING - A/T (4L60-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. For 2003 4L80-E transmission, see «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e) under REMOVAL & INSTALLATION in SERVICING - A/T (4L80-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. Turn ON the ignition, with the engine OFF. Connect a 10-amp fused jumper between the starter motor relay coil control circuits of the PNP switch. With the transmission in PARK, turn the ignition switch to the START position. Does the test lamp illuminate? If yes, go to step 18 . If no, go to step 15 .
  11. Turn OFF the ignition. Disconnect the starter motor relay. See «RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) under REPAIR INSTRUCTIONS. Connect a test lamp between the battery positive voltage circuit of the starter motor relay switch circuit and a good ground. Does the test lamp illuminate? If yes, go to next step. If no, go to step 23 .
  12. Connect a 30-amp fused jumper between the battery positive voltage circuit of the starter motor relay switch circuit and the supply voltage circuit of the starter solenoid. Does the engine crank? If yes, go to step 17 . If no, go to next step.
  13. Does the fuse in the jumper open? If yes, go to step 24 . If no, go to step 16 .
  14. Test the control circuit of the starter motor relay for an open or high resistance. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 25 .
  15. Test the supply voltage circuit of the starter motor relay coil circuit for an open or high resistance. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 21 .
  16. Test the supply voltage circuit of the starter solenoid for an open or high resistance. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 22 .
  17. Inspect for poor connections at the starter motor relay. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 25 .
  18. If equipped with an automatic transmission, inspect for poor connection at the PNP switch harness connector. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. If okay, perform one of the following: For 2003 4L60-E transmissions, go to «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__parkneutral-position-switch) under ADJUSTMENTS in SERVICING - A/T (4L60-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. For 2003 4L80-E transmissions, go to «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__parkneutral-position-switch) under ADJUSTMENTS in SERVICING - A/T (4L80-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. If equipped with a manual transmission, inspect for poor connection at the clutch pedal position switch harness connector. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 26 .
  19. Inspect for poor connections at the harness connector of the PCM. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 29 . If no, go to next step.
  20. The replacement PCM must be programmed. For 2003 4.3L, see «POWERTRAIN CONTROL MODULE»(/chevrolet/chevy-express-h2500/2003-2003/remont/testing-diagnostics/#engine-controls-self-diagnostics-43l__powertrain-control-module) under PROGRAMMING in SELF-DIAGNOSTICS - 4.3L article in FAULT ISOLATION in ENGINE PERFORMANCE. For 2003 4.8L, 5.3L & 6.0L, see «POWERTRAIN CONTROL MODULE»(/chevrolet/chevy-express-h2500/2003-2003/remont/testing-diagnostics/#engine-controls-self-diagnostics-48l-53l-60l-gasoline__powertrain-control-module) under PROGRAMMING in SELF-DIAGNOSTICS - GASOLINE article in FAULT ISOLATION in ENGINE PERFORMANCE. Replace the PCM. For 2003, see «POWERTRAIN CONTROL MODULE»(/chevrolet/chevy-express-h2500/2003-2003/remont/removal-installation/#engine-controls-removal-installation-gasoline__powertrain-control-module) under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION - GASOLINE article in ENGINE PERFORMANCE. Is action complete? If yes, go to step 29 .
  21. Inspect for poor connections at the ignition switch harness connector. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 27 .
  22. Inspect for poor connections at the starter solenoid. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 29 . If no, go to step 28 .
  23. Repair the open or high resistance in the battery positive voltage circuit of the starter motor relay switch circuit. Did you complete the repair? If yes, go to step 29 .
  24. Repair the short to ground in the supply voltage circuit of the starter solenoid. Did you complete the repair? Go to step 29 .
  25. Replace the starter relay. See «RELAY REPLACEMENT (WITHIN AN ELECTRICAL CENTER)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) under REPAIR INSTRUCTIONS. After repairs are complete, go to step 29 .
  26. Replace the PNP switch. For 2003 4L60-E transmission, see «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e) under REMOVAL & INSTALLATION in SERVICING - A/T (4L60-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. For 2003 4L80-E transmission, see «PARK/NEUTRAL POSITION SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e) under REMOVAL & INSTALLATION in SERVICING - A/T (4L80-E) article in AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. After repairs are complete, go to step 29 .
  27. Replace the ignition switch. See STEERING COLUMNS article in STEERING. After repairs are complete, go to step 29 .
  28. Replace the starter. See «STARTER MOTOR REPLACEMENT (4.3L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-43l) or «STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-48l-53l) under REPAIR INSTRUCTIONS. After repairs are complete, go to next step.
  29. Operate the system for which the symptom occurred. Did you correct the condition? If yes, the system is okay. If no, go to step 2 .

STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK

  1. Did you perform the Engine Electrical Diagnostic System Check? If yes, go to next step. If no, go to «DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) .
  2. Turn the ignition to the START position. Did the starter solenoid click? If yes, go to next step. If no, go to «STARTER SOLENOID DOES NOT CLICK»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-solenoid-does-not-click) .
  3. Inspect the engine and belt drive system for mechanical binding seized engine, seized generator. Does the engine move freely? If yes, go to next step. If no, go to «BASIC TROUBLE SHOOTING»(/chevrolet/chevy-express-h2500/2003-2003/remont/basic-trouble-shooting/#basic-trouble-shooting-general-information) article in GENERAL INFORMATION.
  4. Test the battery positive cable between the battery and the starter solenoid for high resistance. Did you find and correct the condition? If yes, go to step 8 . If no, go to next step.
  5. Test the ground circuit between the battery and the starter motor for a high resistance. Did you find and correct the condition? If yes, go to step 8 . If no, go to next step.
  6. Inspect for poor connections at the starter. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. Did you find and correct the condition? If yes, go to step 8 . If no, go to next step.
  7. Replace the starter. See «STARTER MOTOR REPLACEMENT (4.3L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-43l) or «STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-48l-53l) under REPAIR INSTRUCTIONS. After repairs are complete, go to next step.
  8. Operate the system for which the symptom occurred. Did you correct the condition? If yes, the system is okay. If no, go to step 2 .

ENGINE CRANKS SLOWLY

Perform the following checks

  1. Battery - Battery Inspection/Test. For 2003, see «BATTERY TESTING & INSPECTION»(/chevrolet/chevy-express-h2500/2003-2003/remont/charging-system/#charging-system__battery-testing-inspection) under ON-VEHICLE TESTING in GENERATORS & REGULATORS article in CHARGING SYSTEM in ELECTRICAL.
  2. Wiring - Inspect the wiring for damage. Inspect all connections to the starter motor, solenoid, battery and all ground connections. See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL.
  3. Engine - Make sure the engine is not seized. See «BASIC TROUBLE SHOOTING»(/chevrolet/chevy-express-h2500/2003-2003/remont/basic-trouble-shooting/#basic-trouble-shooting-general-information) article in GENERAL INFORMATION.

If the battery, the wiring and the engine are functioning properly and the engine continues to crank slowly, replace the starter motor. See

or

under REPAIR INSTRUCTIONS.

Diagnostic Aids

  1. Inspect the flywheel ring gear for damage or unusual wear.
  2. Shim the starter if applicable.
  3. In order to add pinion to ring gear clearance a full size shim must be used. DO NOT shim only 1 starter mounting bolt. There are 3 shims available in different shapes for clearance. All are 0.039" (1 mm) thick.
  1. Did you perform the Engine Electrical Diagnostic System Check? If yes, go to next step. If no, go to «DIAGNOSTIC SYSTEM CHECK - ENGINE ELECTRICAL»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system) .
  2. Start the engine. Does the starter operate normally? See «INTERMITTENTS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__intermittents) under SYMPTOMS - ENGINE ELECTRICAL. If yes, go to next step.
  3. Start the engine while listening to the starter motor turn. Is there a loud "whoop", it may sound like a siren if the engine is revved while the starter is engaged after the engine starts, but while the starter is still held in the engaged position? If yes, go to step 6 . If no, go to next step.
  4. Do you hear a "rumble", a "growl", or, in some cases, a "knock" as the starter is coasting down to a stop after starting the engine? If yes, go to step 7 . If no, go to next step.
  5. This is often diagnosed as a starter drive gear hang-in or a weak solenoid. When the engine is cranked, do you hear a high-pitched whine after the engine cranks and starts normally? If yes, go to step 8 . If no, go to step 7 .
  6. Inspect the flywheel ring gear for chipped gear teeth, missing gear teeth and milled teeth. Is the flywheel bent, or does it have damaged teeth? If yes, go to step 9 . If no, go to step 10 .
  7. Remove the starter motor. See «STARTER MOTOR REPLACEMENT (4.3L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-43l) or «STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-48l-53l) under REPAIR INSTRUCTIONS. Inspect the starter motor bushings and clutch gear. Does the clutch gear have chipped or milled teeth or worn bushings? If yes, go to step 10 . If no, go to step 9 .
  8. Shim the starter motor away from the flywheel by adding shims between the starter motor and the engine block one at a time. Flywheel runout may make this noise appear to be intermittent. Did you complete the repair? If yes, go to step 11 .
  9. Replace the flywheel. Remove transmission to access flywheel. For 2003, see «TRANSMISSION»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation) under REMOVAL & INSTALLATION in REMOVAL & INSTALLATION - A/T. After repairs are complete, go to step 11 .
  10. Replace the starter motor. See «STARTER MOTOR REPLACEMENT (4.3L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-43l) or «STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L)»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__starter-motor-replacement-48l-53l) under REPAIR INSTRUCTIONS. After repairs are complete, go to next step.
  11. Operate the system in order to verify the repair. Did you correct the condition? If yes, the system is okay. If no, go to step 3 .

Removal

Note. Required Tool: Relay Puller Pliers (J-43244).

  1. Remove the electrical center cover. Locate the relay. See «FUSES & CIRCUIT BREAKERS»(/chevrolet/chevy-express-h2500/2003-2003/remont/fuses-circuit-breakers/#fuses-circuit-breakers) article in ELECTRICAL. NOTE: Always note the orientation of the relay. Ensure that the electrical center is secure, as not to put added stress on the wires or terminals.
  2. Using the Relay Puller Pliers, position the tool on opposing corners of the relay. (Scheme 2) CAUTION: Use the Relay Puller Pliers to pull the relay straight out from the electrical center terminals. The use of pliers or a flat bladed tool could damage the electrical center.
  3. Remove the relay from the electrical center.

Scheme 2

Scheme 2
Scheme 2

Installation

  1. Install the relay in the same position as removed.
  2. Install the electrical center cover.

STARTER MOTOR REPLACEMENT (4.3L)

WARNINGBefore servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
  1. Disconnect the battery negative cable. Raise the vehicle.
  2. Remove the starter motor brackets and shields, if equipped. (Scheme 3)
  3. Disconnect the wires from the starter solenoid. (Scheme 4)
  4. Remove the bolts and the shims, if present, from the starter motor. (Scheme 5) Remove the starter motor from the engine.

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Install the starter motor to the engine. (Scheme 5) Install the bolts and the shims, if present, to the starter motor. Tighten the bolts to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  2. Connect the wires to the starter solenoid. (Scheme 4) Tighten the starter lead nut to the solenoid to specification. Tighten the starter solenoid wires to the solenoid to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  3. Install the starter motor brackets and shields. (Scheme 3)
  4. Connect the battery negative cable. Tighten to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).

STARTER MOTOR REPLACEMENT (4.8L, 5.3L & 6.0L)

WARNINGBefore servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
  1. Disconnect the negative battery cable. Raise and suitably support the vehicle.
  2. Remove the right transmission cover bolt. (Scheme 6)
  3. Remove the starter bolts. (Scheme 7) Disconnect the oil level sensor electrical connector. Slide the starter forward until the starter clears the transmission.
  4. Remove the starter solenoid nut. (Scheme 8) Remove the starter lead from the solenoid stud.
  5. Remove the starter lead nut. Remove the positive cable from the starter stud. Place the starter on a workbench.
  6. Unsnap the transmission cover from the starter. (Scheme 9)
  7. If necessary, remove the starter shield. (Scheme 10)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. If necessary, install the starter shield. (Scheme 10)
  2. Snap the transmission cover to the starter. (Scheme 9)
  3. Install the positive cable to the starter stud. (Scheme 8) Install the starter lead nut. Tighten the starter lead nut to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  4. Install the starter solenoid lead to the solenoid stud. Install the starter solenoid nut. Tighten the starter solenoid nut to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  5. Slide the starter rearward. (Scheme 7) Install the starter bolts. Tighten the starter bolts to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  6. Connect the oil level sensor electrical connector.
  7. Install the right transmission cover bolt. (Scheme 6) Tighten the transmission cover bolt to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).
  8. Lower the vehicle. Connect the negative battery cable. Tighten to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/starter/#starting-system__fastener-tightening-specifications).

The PG-260 is a non-repairable starter motor. It has pole pieces that are arranged around the armature within the starter housing. When the solenoid windings are energized, the pull-in winding circuit is completed to ground through the starter motor. The hold-in winding circuit is completed to ground through the solenoid. The windings work together magnetically to pull in and hold in the plunger. The plunger moves the shift lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the flywheel ring gear on the engine. At the same time, the plunger closes the solenoid switch contacts in the starter solenoid. Full battery voltage is then applied directly to the starter motor and it cranks the engine.

As soon as the solenoid switch contacts close, current stops flowing thorough the pull-in winding as battery voltage is now applied to both ends of the windings. The hold-in winding remains energized; its magnetic field is strong enough to hold the plunger, shift lever, starter drive assembly and solenoid switch contacts in place to continue cranking the engine. When the engine starts, the pinion gear overrun sprag protects the armature from excessive speed until the switch is opened.

When the ignition switch is released from the CRANK position, voltage is removed from the starter solenoid "S" terminal. Current flows from the motor contacts through both windings to ground at the end of the hold-in winding. However, the direction of the current flow through the pull-in winding is now in the opposite direction of the current flow when the winding was first energized.

The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the windings, along with the help of the return spring, cause the starter drive assembly to disengage and the solenoid switch contacts to open simultaneously. As soon as the contacts open, the starter motor is turned off.