Starting System Chevrolet Malibu V

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

ACHIEVA, GRAND AM & SKYLARK

COMPONENT LOCATIONS

MALIBU & CUTLASS

COMPONENT LOCATIONS

TRANSAXLE RANGE SWITCH

Remove negative battery cable. Remove shift linkage. Remove transaxle range switch electrical connector. Loosen transaxle range switch mounting blots. Place shift shaft in Neutral position and align flats of shift shaft with switch. Place Park Neutral Position Switch Alignment (J41545) tool and rotate switch until tool drops into position. (Scheme 2) Tighten mounting bolts and remove alignment tool. After switch adjustment, verify that engine will only start in Park or Neutral. If engine will start in any other position re-adjust switch.

Scheme 2

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 appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT section

1. «ANTI-THEFT SYSTEM»(/chevrolet/malibu/v-1996-2000/remont/door-locks-anti-theft-systems/#anti-theft-system) - Cutlass & Malibu
2. «ANTI-THEFT SYSTEM»(ref-33516) - Achieva, Grand Am & Skylark

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

1. «TESTS W/CODES»(/chevrolet/malibu/v-1996-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-24l) - Malibu - 2.4L
2. «TESTS W/CODES»(ref-33404) - Achieva & Grand Am - 2.4L
3. «TESTS W/CODES»(/chevrolet/malibu/v-1996-2000/remont/testing-diagnostics/#engine-controls-tests-wcodes-31l) - Malibu & Cutlass - 3.1L
4. «TESTS W/CODES»(ref-33405) - Achieva, Grand Am & Skylark - 3.1L

Check 60-amp IGN SW fuse.

Check 40-amp IGN SW-BATT1 fuse.

STARTER NOISE

Note. 2.4L 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 3)
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. 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»(/chevrolet/malibu/v-1996-2000/remont/starter/#starting-system__removal-installation).

Scheme 3

ON-VEHICLE TESTING

1. Achieva, Grand Am & Skylark, see: «AIR BAG RESTRAINT SYSTEM»(ref-33517)
2. Cutlass & Malibu, see: «AIR BAG RESTRAINT SYSTEM»(/chevrolet/malibu/v-1996-2000/remont/airbag/#supplemental-inflatable-restraint-system)

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, STARTER SOLENOID DOES NOT CLICK

1. Place gear selector in Park (A/T). Turn ignition switch to START position. Using DVOM, measure voltage between starter solenoid terminal "S" (Purple wire) and ground. See «WIRING DIAGRAMS»(/chevrolet/malibu/v-1996-2000/remont/starter/#starting-system). If battery voltage exists, go to next step. If battery voltage does not exist, go to step 3).
2. Using DVOM, measure voltage between starter solenoid terminal "S" (Purple wire) and starter motor mounting bolts. Turn ignition switch to START position. If battery voltage exists, replace starter solenoid and recheck symptom. If battery voltage does not exist, clean starter motor and starter motor mounting bolts, creating a good ground to engine block. Check for rust, dirt or excess paint and recheck symptom.
3. Disconnect transaxle range switch connector C1. Turn ignition switch to START position. Using DVOM, measure voltage between transaxle range switch connector C1, terminal "G" (Yellow wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 5).
4. Using DVOM, measure resistance at transaxle range switch connector C1 between terminals "E" and "G". If resistance is 0-2 ohms, check for open in Purple wire between transaxle range switch connector C1, terminal "E" and starter solenoid terminal "S". Repair as necessary and recheck symptom. If resistance is not 0-2 ohms, check transaxle range switch. Adjust or replace switch as necessary and recheck symptom. See «TRANSAXLE RANGE SWITCH»(/chevrolet/malibu/v-1996-2000/remont/starter/#starting-system__transaxle-range-switch) under ADJUSTMENTS.
5. Using DVOM, backprobe underhood bussed electrical center. Measure voltage at between underhood bussed electrical center connector C3, terminal F11 and ground. (Scheme 5) Turn ignition switch to START position. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 7).
6. Using DVOM, backprobe underhood bussed electrical center. Measure voltage between underhood bussed electrical center connector C1, terminal F11 and ground. (Scheme 4) Turn ignition switch to START position. If battery voltage exists, check for open in Yellow wire between underhood bussed electrical center connector C1, terminal F11 and transaxle range switch connector C1, terminal "G". If battery voltage does not exist, replace underhood bussed electrical center and recheck symptom.
7. Using DVOM, backprobe ignition switch. Measure voltage between ignition switch connector C2, terminal "A" and ground. Turn ignition switch to START position. If battery voltage exists, go to next step. If battery voltage does not exist, go to step 9).
8. Using DVOM, backprobe ignition switch. Measure voltage between ignition switch connector C1, terminal "B" and ground. Turn ignition switch to START position. If battery voltage exists, repair open circuit in Yellow wire between ignition switch connector C1, terminal "B" and underhood bussed electrical center connector C1, terminal F11. If battery voltage does not exist, replace ignition switch and recheck symptom.
9. Using DVOM, backprobe underhood bussed electrical center. Measure voltage between underhood bussed electrical center connector C4, terminal "A" and ground. If battery voltage exists, repair open circuit in Red wire between ignition switch connector C2, terminal "A" and underhood bussed electrical center connector C4, terminal "A". If battery voltage does not exist, replace ignition switch and recheck symptom.

Scheme 4

Scheme 5

ENGINE DOES NOT CRANK, SOLENOID CLICKS

1. Remove 20-amp F/P INJ fuse. F/P INJ fuse is located in underhood fuse block. Turn ignition switch to START position. Using a DVOM, measure voltage between battery positive and negative terminals. Crank engine for at least 15 seconds. If voltage is 9.6 volts or more, go to step 3). If voltage is less than 9.6 volts, go to next step.
2. Load test battery. If battery fails load test, replace battery. If load test is okay, repair or replace starter motor.
3. Using DVOM, measure voltage between battery negative terminal and engine block while cranking engine for 15 seconds. If voltage is less than 0.5 volt, go to next step. If voltage is 0.5 volt or more, clean negative battery cable connections and retest. If voltage is still 0.5 volt or more, replace battery negative cable.
4. Using DVOM, measure voltage between battery positive terminal and starter solenoid terminal "B" (Black wire) while cranking engine for 15 seconds. If voltage is less than 0.5 volt, repair or replace starter motor assembly. If voltage is 0.5 volt or more, clean positive battery cable connections and retest. If voltage is still 0.5 volt or more, replace battery positive cable.

PRELIMINARY TESTS

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

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 2) 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 «HOLD-IN WINDINGS SPECIFICATIONS»(/chevrolet/malibu/v-1996-2000/remont/starter/#starting-system) table. Check ammeter reading. Turn off carbon pile and open switch. Refer to the «HOLD-IN WINDINGS SPECIFICATIONS»(/chevrolet/malibu/v-1996-2000/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 2) 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 6

STARTER NO-LOAD TEST

1. Secure starter in vise. Turn carbon pile off and open switch. Connect test equipment to starter as illustrated. (Scheme 7) Turn switch on and adjust carbon pile until voltage reads as specified. See «STARTER NO-LOAD TEST SPECIFICATIONS»(/chevrolet/malibu/v-1996-2000/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 the «STARTER NO-LOAD TEST SPECIFICATIONS»(/chevrolet/malibu/v-1996-2000/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, 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 7

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). 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 8) 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 8

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 9) 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 9

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, 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

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 10)
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 11)

Scheme 10

Scheme 11

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 2.4L engines, starters cannot be shimmed. Noise condition, requiring shims, can only be corrected by replacing starter.

Removal (2.4L)

Disconnect negative battery cable. Remove air inlet duct at throttle body and top starter bolt. Raise vehicle and support vehicle. Remove lower closeout panel. Remove lower starter bolt. Position engine wiring harness aside. Position starter for access to solenoid wiring. Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. Remove shims and note arrangement for reassembly. Remove starter.

Removal (3.1L)

Disconnect negative battery cable. Raise and support vehicle. Remove lower closeout panel. Remove starter mounting bolts. Remove shims and note arrangement for reassembly. Lower starter. Remove starter solenoid terminal "S" nut and battery cable nut. Separate wiring from starter. 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 .

STARTER & SOLENOID

Note. When reassembling starter and solenoid, use grease (10477431 or 1960954) for lubrication. Use of other greases may cause starter failure.

Note. For exploded view of starter, refer to illustrations. (Scheme 12)

Disassembly

Remove solenoid by turning 90 degrees while pulling solenoid out of starter. If shift lever 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.

Assembly

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. Pinion stop color ring is not re-used.

Lubricate solenoid core with grease. Apply grease evenly around inside edge or solenoid core. Apply thickly to first .5" (13 mm) inside edge of core. Plunger movement will distribute grease properly. Soak new drive end bushing in oil (for at least 30 minutes) before installation.

Scheme 12

Scheme 13

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• ANTI-THEFT SYSTEM
• TESTS W/CODES
• TESTS W/CODES
• AIR BAG RESTRAINT SYSTEM
• PARASITIC LOAD EXPLANATION & TEST PROCEDURES
• COMPUTER RELEARN PROCEDURES
• REMOVAL & INSTALLATION
• WIRING DIAGRAMS
• TRANSAXLE RANGE SWITCH