Starting System Chevrolet Corvette C5

DESCRIPTION & OPERATION

Corvette uses starter PG260 M which is serviceable only by complete replacement. Starter motor features pole pieces that are arranged around armature within starter housing. Drive housing encloses shift lever, shift lever mechanism, and solenoid plunger to protect them from exposure to ice, dirt, and other elements.

Models equipped with automatic transaxle utilize a Park/Neutral Position (PNP) switch or transaxle range switch incorporated within starter circuit to allow starter operation only when vehicle is in Park or Neutral. Models equipped with manual transaxle utilize a Clutch Pedal Position (CPP) switch incorporated within starter circuit to prevent starter operation with clutch pedal released, allowing starter operation only when clutch pedal is depressed. Moving ignition switch to CRANK position sends battery voltage signal through PNP switch (A/T) or CPP switch (M/T) on through theft deterrent relay and then to Body Control Module (BCM) for ground. BCM verifies it has received a valid theft password before energizing theft deterrent relay. Battery voltage signal is supplied to starter solenoid when theft deterrent relay is activated.

When voltage is applied to solenoid, voltage is applied to solenoid windings which causes movement of solenoid plunger and shift lever, causing drive pinion to engage flywheel and close solenoid switch contacts. (Scheme 1) When solenoid switch contacts close, starter motor energizes and cranks engine. As engine starts, pinion overrun clutch protects armature from excessive speed until ignition switch is opened and plunger return spring disengages pinion.

Scheme 1

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TROUBLE SHOOTING

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

TROUBLE SHOOTING HINTS

Note. Refer to appropriate wiring diagram to verify wire color and connector terminal identification. See WIRING DIAGRAMS .

Check IGN 2 (60-amp) fuse, STARTER (60-amp) fuse, and CRK (10-amp) fuse in instrument panel electrical center. Note condition and operation of SECURITY indicator light. If indicator stays on or flashes continuously, see appropriate 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 appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

STARTER NOISE

Note. Always check flywheel ring gear for signs of damage.

1. Start engine while observing noise from starter motor. If a noise other than a loud, siren-like "whoop" sound is heard after engine starts, go to next step. If a loud, siren-like "whoop" sound is heard after engine starts, check flywheel ring gear for chipped, missing or milled teeth. If flywheel is okay, go to step 4 . If flywheel is bent or teeth are damaged, replace flywheel. See appropriate AUTOMATIC TRANSMISSION REMOVAL or MANUAL TRANSMISSION REMOVAL article in AUTOMATIC TRANSMISSIONS or MANUAL TRANSMISSIONS.
2. If a noise other than a "rumble", "growl" or "knock" sound is heard as starter is coasting to a stop after starting engine, go to next step. If a "rumble", "growl" or "knock" sound is heard as starter is coasting to a stop after starting engine, go to step 4 .
3. If a noise other than a high-pitched whine is heard while cranking engine, go to next step. If a high-pitched whine is heard while cranking engine, distance between starter pinion and flywheel is too small. Shim starter away from flywheel by adding shims one at a time and rechecking operation. Ensure starter-to-engine bolts are tightened correctly. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system__torque-specifications) .
4. Remove starter. See «STARTER»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Inspect starter motor bushings and clutch gear. Replace starter as necessary. During initial starter motor installation, shim(s) are not used. If shim(s) are present, install shim(s) in original location with replacement starter. Ensure starter-to-engine bolts are tightened correctly. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system__torque-specifications) . If starter checks okay, check flywheel ring gear for chipped, missing or milled teeth. Replace flywheel as necessary. See appropriate AUTOMATIC TRANSMISSION REMOVAL or MANUAL TRANSMISSION REMOVAL article in AUTOMATIC TRANSMISSIONS or MANUAL TRANSMISSIONS.

ON-VEHICLE TESTING

Information not available from manufacturer.

SYSTEM TESTS

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.

ENGINE DOES NOT CRANK, STARTER SOLENOID CLICKS

1. Turn ignition switch to START position. If starter solenoid clicks and engine does not crank, go to next step. If starter solenoid does not click, go to «ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system__engine-does-not-crank-starter-solenoid) .
2. Inspect engine and belt drive system for mechanical binding. Repair as necessary. If engine moves freely, go to next step.
3. Check positive battery cable between starter and underhood fuse block for an open or high resistance. Repair as necessary and retest operation. If positive battery cable checks okay, go to next step.
4. Check starter motor ground circuit for high resistance. See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Repair as necessary and retest operation. If starter motor ground circuit checks okay, go to next step.
5. Check for poor connections at starter solenoid. Repair as necessary and retest operation. If starter solenoid connections are okay, replace starter. See «STARTER»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Retest operation.

ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK

1. Turn ignition switch to START position. If engine cranks, system is okay at this time. If engine does not crank, go to next step.
2. Locate theft deterrent relay. See «COMPONENT LOCATIONS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system__component-locations) . Listen for a "click" from theft deterrent relay while turning ignition switch to START position. If a "click" sound is heard from theft deterrent relay while turning ignition switch to START position, go to step 6 . If no "click" sound is heard from theft deterrent relay while turning ignition switch to START position, go to next step.
3. Disconnect theft deterrent relay. Connect a test light between ground and theft deterrent relay connector terminal C2 (Yellow wire). With transmission in Park (A/T), or clutch pedal depressed (M/T), turn ignition switch to START position. If test light illuminates, go to next step. If test light does not illuminate, go to step 5 .
4. Connect test light between theft deterrent relay connector terminals C2 (Yellow wire) and A1 (Yellow/Black wire). With transmission in Park (A/T), or clutch pedal depressed (M/T), turn ignition switch to START position. If test light illuminates, go to step 12 . If test light does not illuminate, go to step 9 .
5. Turn ignition off. Locate PNP switch (A/T) or CPP switch (M/T). See «COMPONENT LOCATIONS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system__component-locations) . Disconnect PNP switch (A/T) or CPP switch (M/T). Turn ignition on. On models equipped with automatic transmission, connect 10-amp fused jumper between PNP switch connector C1 terminals "E" (Purple wire) and "G" (Yellow wire). On models equipped with manual transmission, connect 10-amp fused jumper between CPP switch connector terminals "A" (Purple wire) and "B" (Yellow wire). On all models, with test light still connected between theft deterrent relay connector terminals C2 (Yellow wire) and A1 (Yellow/Black wire), turn ignition switch to START position while observing test light. If test light illuminates, go to step 13 . If test light does not illuminate, go to step 10 .
6. Turn ignition off. Disconnect theft deterrent relay. Connect a test light between ground and theft deterrent relay connector terminal C1 (Red wire). If test light illuminates, go to next step. If test light does not illuminate, go to step 17 .
7. Connect 30-amp fused jumper between theft deterrent relay connector terminals C1 (Red wire) and A2 (Purple wire). If starter engages, go to step 12 . If starter does not engage, go to next step.
8. If 30-amp fuse in jumper goes open, go to step 18 . If 30-amp fuse in jumper does not go open, go to step 11 .
9. Check for open or high resistance in Yellow/Black wire between theft deterrent relay connector terminal A1 and Green Body Control Module (BCM) 16-pin connector C3 terminal B7. See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Repair as necessary and retest operation. If Yellow/Black wire checks okay, go to step 14 .
10. Check for open or high resistance in Yellow wire between theft deterrent relay connector terminal C2 and PNP switch (A/T) or CPP switch (M/T). See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Repair as necessary and retest operation. If Yellow wire checks okay, go to step 15 .
11. Check for open or high resistance in Purple wire between theft deterrent relay connector terminal A2 and starter solenoid "S" terminal. See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Repair as necessary and retest operation. If Purple wire checks okay, go to step 16 .
12. Check for poor connections at theft deterrent relay. Repair as necessary and retest operation. If theft deterrent relay connections check okay, go to step 19 .
13. On models equipped with automatic transmission, check for poor connection at PNP switch. On models equipped with manual transmission, check for poor connection at CPP switch. On all models, repair as necessary and retest operation. If PNP switch (A/T) or CPP switch (M/T) connections check okay, go to step 20 .
14. Check for poor connection at Green BCM 16-pin connector C3. Repair as necessary and retest operation. If BCM connection is okay, go to step 21 .
15. Gain access to ignition switch electrical connector and check for poor connections. See IGNITION SWITCH under REMOVAL & INSTALLATION in ANALOG INSTRUMENT PANELS - CORVETTE article. Repair as necessary and retest operation. If ignition switch connections are okay, replace ignition switch. Retest operation.
16. Check for poor connections at starter solenoid. Repair as necessary and retest operation. If starter solenoid connections are okay, replace starter. See «STARTER»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Retest operation.
17. Locate and repair open or high resistance in Red wire between theft deterrent relay connector terminal C1 and STARTER fuse (60-amp) located in instrument panel electrical center. See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Retest operation.
18. Repair short to ground in Purple wire between theft deterrent relay connector terminal A2 and starter solenoid "S" terminal. See «WIRING DIAGRAMS»(/chevrolet/corvette/c5-1997-2004/remont/starter/#starting-system) . Retest operation.
19. Replace theft deterrent relay. Retest operation.
20. On models equipped with automatic transmission, replace PNP switch. On models equipped with manual transmission, replace CPP switch. Retest operation.
21. Replace BCM. See BODY CONTROL MODULE (BCM) under REMOVAL & INSTALLATION in BODY CONTROL MODULES - CORVETTE article.

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.

BENCH TESTING

Information is not available from manufacturer.

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.

Removal

1. Disconnect negative battery cable. Raise and support vehicle. Disconnect heated oxygen sensor connectors. Remove exhaust pipe-to-exhaust manifold retaining nuts. Remove intermediate exhaust pipe-to-rear exhaust pipe retaining bolts. Remove front and rear exhaust hanger bolts as necessary. Remove intermediate exhaust pipe assembly.
2. Remove starter solenoid terminal "S" nut and positive battery cable nut. Separate wiring from starter. Support starter. Remove starter mounting bolts. Remove shims and note arrangement for reassembly (if equipped). Remove starter assembly.

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 positive battery cable and wiring to solenoid terminals. Tighten solenoid wiring retaining nuts to specification. Ensure shims are installed in original location (if equipped). Tighten starter mounting bolts. See TORQUE SPECIFICATIONS . Install intermediate exhaust pipe using NEW gaskets. To complete installation, reverse removal procedure. Reprogram Remote Keyless Entry (RKE) transmitters. See SYSTEM PROGRAMMING in REMOTE KEYLESS ENTRY SYSTEMS - CORVETTE article in ACCESSORIES & EQUIPMENT.

OVERHAUL

Note. Starter assembly is not serviceable and should be replaced as complete unit.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• WIRING DIAGRAMS
• TORQUE SPECIFICATIONS
• ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK
• COMPONENT LOCATIONS