Starting System (G Series) Chevrolet Chevy Van G1500

DESCRIPTION

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.

On starters with the SD designation, used on gasoline engines only, the pinion is driven directly by the armature shaft. Wound field coils energize pole pieces that are arranged around the armature.

Scheme 1

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TROUBLE SHOOTING

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

TROUBLE SHOOTING HINTS

Note condition of SECURITY indicator light. If indicator stays on or flashes continuously troubleshoot anti-theft system. 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 appropriate TESTS W/CODES article in ENGINE PERFORMANCE section. Refer to menu below.

1. For 4.3L, see «TESTS W/CODES - 4.3L»(/chevrolet/chevy-van-g1500/1996-1998/remont/testing-diagnostics/#engine-controls-tests-wcodes-43l)
2. For 5.0L, see «TESTS W/CODES - 5.0L»(/chevrolet/chevy-van-g1500/1996-1998/remont/testing-diagnostics/#engine-controls-tests-wcodes-50l-g-vans)
3. For 5.7L, see «TESTS W/CODES - 5.7L»(/chevrolet/chevy-van-g1500/1996-1998/remont/testing-diagnostics/#engine-controls-tests-wcodes-g-series)
4. For 6.5L, see «TESTS W/CODES - 6.5L»(/chevrolet/chevy-van-g1500/1996-1998/remont/testing-diagnostics/#engine-controls-tests-wcodes-65l-diesel-g-series)
5. For 7.4L, see «TESTS W/CODES - 7.4L»(/chevrolet/chevy-van-g1500/1996-1998/remont/testing-diagnostics/#engine-controls-tests-wcodes-74l-g-series)

Check 40-amp IGN-A fuse, located in underhood fuse-relay center. Check 10-amp CRANK No. 8 fuse, located in instrument panel fuse block.

STARTER NOISE

Note. Check flywheel ring gear for damage.

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. Locate high spot on flywheel before checking pinion-to-flywheel clearance. 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.
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 starter should be moved away from flywheel, add shims as necessary. If using.039" (1.0 mm) long shims, do not exceed 2 shims. If using.015" (.38 mm) long shims, do not exceed 3 shims. If condition is not corrected, and pinion-to-flywheel clearance has been reached, short shims may be added to outer side of starter motor bolt using.015" (.38 mm) shims. For starter removal, see STARTER under «REMOVAL & INSTALLATION»(/chevrolet/chevy-van-g1500/1996-1998/remont/starter/#starting-system-g-series__removal-installation).

Scheme 2

ON-VEHICLE TESTING

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

STARTER DRAW TEST (DIESEL)

1. Disable fuel system. Connect ammeter to negative battery cable. Crank engine and observe ammeter readings. If readings are over 360 amps, repair or replace starter assembly. If readings are under 300 amps, repair or replace battery cable or connections.

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

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

ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK

1. Place gear selector in Park. Place ignition switch to START position. Using a DVOM, measure voltage between starter solenoid connector terminal "S" (Purple wire) and engine ground. If voltage is lower than 9.6 volts, go to next step. If voltage is 9.6 volts, clean starter motor mounting blots, starter motor and mounting surface, and repeat test. If starter still does not engage, replace starter.
2. Remove starter relay from underhood fuse-relay center. See «COMPONENT LOCATIONS»(/chevrolet/chevy-van-g1500/1996-1998/remont/starter/#starting-system-g-series) table. Connect a test light, between starter relay connector terminal A6 and ground. If test light illuminates, go to next step. If test light does not illuminate, check for open in Red sire between 40-amp IGN-A fuse connector terminal M6 and starter relay connector terminal A6.
3. Disconnect starter solenoid connector terminal "S" (Purple wire). Connect a self-powered test light between starter relay connector terminal B4 and starter solenoid terminal connector terminal "S" (Purple wire). If test light illuminates, go to next step. If test light does not illuminate, check for an open in Purple wire between starter relay connector terminal B4 and starter solenoid connector terminal "S".
4. Reconnect starter solenoid connector terminal "S" (Purple wire). Connect a self-powerd test light between starter relay connector terminal A4 (Black wire) and ground. If test light illuminates, go to next step. If test light does not illuminates, check for open in Black wire between starter relay connector terminal A4 and ground. Ground connector is located at engine harness, at generator bracket (4.3L and 6.5L diesel engines) or left front of engine harness, at A/C compressor (5.0L, 5.7L or 7.4L engines).
5. Place gear selector in Park position. Connect test light between starter relay connector terminal B6 (Yellow wire) and ground. Turn ignition switch to START position. If test light illuminates, replace starter relay. If test light does not illuminate, go to next step.
6. Place gear selector in Park position. Disconnect park/neutral position switch connector C1. Turn ignition switch to START position. Connect a self-powerd test light between park/neutral position switch connector C1 terminals "E" (Purple wire) and "G" (Yellow wire). If test light illuminates, go to next step. If test light does not illuminate, replace park/neutral position switch.
7. Place gear selector in Neutral position. Disconnect park/neutral position switch connector C1. Turn ignition switch to START position. Connect a self-powerd test light between park/neutral position switch connector C1 terminals "E" (Purple wire) and "G" (Yellow wire). If test light illuminates, go to next step. If test light does not illuminate, replace park/neutral position switch.
8. Connect a self-powerd test light between park/neutral position switch connector C1 terminal "G" (Yellow wire) and starter relay connector terminal B6 (Yellow wire). If test light illuminates, go to next step. If test light does not illuminate, check for open in Yellow wire between park/neutral position switch connector C1 terminal "G" and starter relay connector terminal B6.
9. Locate in-line Black 48-pin C200 connector, located at steering column harness at base of column. Disconnect Black 48-pin C200 connector and connect test light between connector C200 terminal D5 (Red wire). (Scheme 3) If test light illuminates, go to next step. If test light does not illuminate, check for an open in Red wire between 40-amp IGN-A fuse connector terminal M6 and connector C200 terminal D5.
10. Connect a self-powerd test light between 48-pin C200 connector terminal D1 (Yellow wire) and park/neutral position switch connector C1 terminal "E" (Purple wire). If test light illuminates, check for open in Red wire between connector C200 terminal D5 and ignition switch. Also check for an open in Yellow wire between connector C200 terminal D1 and ignition switch. If both wire are okay, replace ignition switch and recheck symptom. If test lamp does not illuminate, check for open in Yellow wire between connector C200 terminal D1 and 10-amp CRANK fuse No. 8 connector terminal D6. Also check for an open in Purple wire between 10-amp CRANK fuse No. 8 connector terminal E5 and park/neutral position switch connector C1 terminal "E".

Scheme 3

SOLENOID CLICKS, ENGINE DOES NOT CRANK

1. On diesel engines, remove fuel pump relay, located in underhood fuse-relay center. On gasoline engines, disconnect ignition coil connector, located at top right side of engine. Turn ignition switch to START position for 15 seconds. Using a DVOM, measure voltage between battery positive and negative terminals. If voltage is greater than 9.6 volts, go to next step. If voltage is 9.6 volts or less, perform battery load test. If battery fails load test, replace battery. If battery passes load test, repair or replace starter motor.
2. Disconnect Black negative battery cable terminal from right engine compartment, near negative battery post. Turn ignition switch to START position. Using a DVOM, measure voltage between battery negative terminal and negative battery cable ground terminal connection located at left engine compartment, near fender well. If voltage is .5 volts or less, go to next step. If voltage is more than .5 volts, check for high resistance between negative battery terminal and negative battery cable ground connection terminal located at left engine compartment, near fender well. Repair as necessary and recheck symptom.
3. Reconnect Black negative battery cable terminal to right engine compartment, near negative battery post. Disconnect Black negative battery cable from left engine compartment, near fender well. Turn ignition switch to START position. Using a DVOM, measure voltage between battery negative terminal and negative battery cable ground terminal connection located at right engine compartment, near negative battery post. If voltage is more than .5 volts, check for high resistance in Black negative battery cable, between battery negative terminal and negative battery cable terminal connection located right engine compartment, near negative battery post. Repair as necessary and recheck symptom.
4. Reconnect Black negative battery cable from left engine compartment, near fender well. If vehicle has diesel engine, go to next step. If vehicle has gasoline engine, go to step 6).
5. Turn ignition switch to START position. Using a DVOM, measure voltage between auxiliary battery negative terminal and ground terminal connection located at left frame rail near auxiliary battery. If voltage is .5 volts or less go to next step. If voltage is more than .5 volts, check for high resistance in Black negative battery cable between auxiliary battery negative terminal and auxiliary battery negative cable terminal connection located at left frame rail near auxiliary battery.
6. Turn ignition switch to START position. Using a DVOM, measure voltage between starter solenoid terminal "B" (Black wire) and battery negative terminal. If voltage is more than 9.0 volts, repair or replace starter. If voltage is 9.0 volts or less, check open in Black wire between starter terminal "B" and positive battery terminal. Repair as necessary and recheck symptom.

PRELIMINARY TESTS

Remove starter from vehicle. See 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 4) 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»(/chevrolet/chevy-van-g1500/1996-1998/remont/starter/#starting-system-g-series) table. Check ammeter reading. Turn off carbon pile and open switch. On all except diesel engines, at 10 volts reading should be 10-20 amps. On diesel engines, at 10 volts reading should be 12-14 amps. 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 above. (Scheme 4) Ground starter solenoid terminal "M". Turn switch on and quickly adjust carbon pile load until voltage reads as specified. Check ammeter reading. Turn off carbon pile and open switch. On all except diesel engines, at 10 volts reading should be 60-85 amps. On diesel engines, at 10 volts reading should be 52-59 amps. If ammeter reading is not as specified, replace starter solenoid.

Scheme 4

STARTER NO-LOAD TEST

1. Secure starter in vise. Turn carbon pile off and open switch. Connect test equipment to starter as illustrated. (Scheme 5) Turn switch on and adjust carbon pile until voltage reads as specified. See «STARTER NO-LOAD TEST SPECIFICATIONS»(/chevrolet/chevy-van-g1500/1996-1998/remont/starter/#starting-system-g-series) 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»(/chevrolet/chevy-van-g1500/1996-1998/remont/starter/#starting-system-g-series) table.
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. If starter vibrates or is noisy, armature may be rubbing against inside of frame and field.

Scheme 5

ARMATURE TEST

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

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 6) 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 6

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 7) 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 7

BRUSHES, SPRINGS & HOLDERS CHECK

If any brushes are damaged (oil-soaked or pitted) or worn more than 90 percent, replace, frame and fields. If brushes are not damaged and still have more than 50 percent of brush material left, 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.

COMMUTATOR END FRAME & BEARING

Replace armature assembly is commutator outer diameter is less than 1.378" (36 mm) or if undercut depth is less than .008" (.2 mm). DO NOT undercut insulation. 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. Install new bearing no deeper then .080 in (2.1 mm).

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. Install new bearing no deeper then .010 in (.4 mm).

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.
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 8)

Scheme 8

REMOVAL & INSTALLATION

Note. Vehicles are designed for starter mounting without shims. A short shim or long 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

On all engines, disconnect negative battery cable. Raise and support vehicle.

On 4.3L and 5.0L, remove starter brackets and shields. 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.

On 5.7L and 7.4L, remove starter mounting bolts. Remove shims and note arrangement for reassembly. Remove starter motor heat shield. Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. Remove starter.

On 6.5L diesel, remove starter motor retaining nut. Remove starter mounting bolts. Remove shims and note arrangement for reassembly. Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. Remove starter.

Installation

To install, reverse removal procedure. Ensure shims are installed in original location. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS .

STARTER & SOLENOID

Note. When reassembleing starter and solenoid, use grease (10477431) for lubrication. Use of other greases may cause starter failure.

Disassembly (All Except 28-MT Starter)

Remove solenoid by turning 90 degrees pulling solenoid out of starter. If shaft needs to be drilled out, a new shaft and retaining ring will be needed for reassembly. Check starter drive for slippage before removing from armature shaft. Pinion stop color ring is not re-used. (Scheme 9)

Scheme 9

Reassembly

1. Apply a small amount of lubricant to armature shaft and to starter drive contact points. Use 2 sets of pliers to snap pinion stop collar over retainer ring.
2. Lubricate solenoid core with grease. Apply grease evenly around inside edge or solenoid core. Apply thickly to first 1/2 (13 mm) inside edge of core. Plunger movement will distribute grease properly. Soak new drive end bushing in oil, before installation, for at least 30 minutes. To install, reverse removal procedure.

Disassembly (28-MT Starter)

1. If stater solenoid assembly boot is torn, cut or damaged, replace solenoid assembly. DO NOT lose small dowel pin installed between frame assembly and gear reduction and drive group. If lost, dowel must be replaced with a.079" x.394" (2 mm x 10 mm) pin. DO NOT remove bearings from armature assembly unless replacement is required.
2. Gear reduction and drive group washers may stick to bracket or to driveshaft and clutch group as bracket is removed. Note position and number of each washer.
3. Save washers to be installed in same position and number at assembly. DO NOT remove bushing plug or bushing from drive housing unless replacement is necessary. Solenoid assembly, clutch drive assembly, brush holder assembly, armature assembly frame and field assembly are serviced as assemblies only. (Scheme 10)

Scheme 10

1. When installing brushes, note that leads may brake off by excessive handling. When installing new pinion stop and stop rings, support driveshaft and clutch under pinion stop. Apply a small amount of lubricant to armature shaft and to starter drive contact points. Use 2 sets of pliers to snap pinion stop collar over retainer ring. Lubricate solenoid core with grease. Apply grease evenly around inside edge or solenoid core. Apply thickly to first 1/2 (13 mm) inside edge of core. Plunger movement will distribute grease properly. To install, reverse removal procedure.

STARTER SPECIFICATIONS

PULL-IN WINDINGS SPECIFICATIONS

STARTER NO-LOAD TEST SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Starting System Schematic (Express & Savana - Diesel). Scheme 11

Starting System Schematic (Express & Savana - Gasoline). Scheme 12

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• TESTS W/CODES - 4.3L
• TESTS W/CODES - 5.0L
• TESTS W/CODES - 5.7L
• TESTS W/CODES - 6.5L
• TESTS W/CODES - 7.4L
• AIR BAG RESTRAINT SYSTEM
• PARASITIC LOAD EXPLANATION & TEST PROCEDURES
• COMPUTER RELEARN PROCEDURES
• REMOVAL & INSTALLATION
• COMPONENT LOCATIONS