Starting System Chevrolet Malibu V рестайлинг

DESCRIPTION & OPERATION

When ignition switch is turned to START position, battery voltage is applied to Park/Neutral Position (PNP) switch (A/T) or Clutch Pedal Position (CPP) switch (M/T). Current passes through PNP switch or CPP switch to starter solenoid only when vehicle is in Park or Neutral position (A/T) or clutch pedal is depressed (M/T). When voltage is applied to solenoid windings, this creates 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 the 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

STARTER APPLICATION

STARTER APPLICATION

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TROUBLE SHOOTING

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

Note condition and operation of SECURITY (Alero & Grand Am) or THEFT SYSTEM (Malibu) 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. Check IGN SW-BATT 1 (40-amp) fuse in underhood junction block. See COMPONENT LOCATIONS. On models equipped with V6 engine, check for correct starter usage. (Scheme 2)and (Scheme 3). If problem is found, repair as necessary. If problem is not found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM.

Scheme 2

Scheme 3

ON-VEHICLE TESTING

Note. Before making electrical checks, visually inspect all terminals for clean, tight connections. Ensure all charging system related fuses are okay. Check generator mounting bolts and drive belt tension. Ensure battery is in good condition prior to testing starting system.

BATTERY TESTING & INSPECTION

Note. Manufacturer recommends using Battery Tester (J-42000) for testing battery. Follow instructions provided with tester.

1. Inspect battery for a cracked, broken or damaged case. If battery case is okay, go to next step. If battery case is not okay, go to step 19 .
2. Compare battery cold cranking amperage and reserve capacity rating to specifications. See «BATTERY SPECIFICATIONS»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) table. If battery meets or exceeds specifications, go to next step. If battery does not meet or exceed specifications, go to step 19 . BATTERY SPECIFICATIONS Application Specification 2.4L (L61) Engine (GM P/N 19001806) Replacement Battery Number 75-5YR Cold Cranking Amps 525 Amps Reserve Capacity Rating 90 Minutes 3.1L (LG8) & 3.4L (LA1) Engines (GM P/N 19001807) Replacement Battery Number 75-6YR Cold Cranking Amps 600 Amps Reserve Capacity Rating 90 Minutes
3. Inspect battery hydrometer display. If hydrometer display shows a Yellow dot, go to next step. If hydrometer display does not show a Yellow dot, go to step 5 .
4. Using a small screwdriver, tap top of hydrometer display to dislodge any air bubbles inside. If hydrometer display still shows a Yellow dot, go to step 19 . If hydrometer display does not show a Yellow dot, go to next step.
5. Turn ignition switch off. Attempt to rotate negative battery cable connector clockwise with light finger pressure. If negative connector rotates, go to next step. If negative connector does not rotate, go to step 7 .
6. Using an INCH lb. torque wrench, record torque value while loosening negative battery cable bolt. If torque is equal to or greater than 89 INCH lbs. (10 N.m), go to step 8 . If torque is less than 89 INCH lbs. (10 N.m), go to next step.
7. Disconnect negative battery cable and go to step 9 .
8. Disconnect negative battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
9. Attempt to rotate positive battery cable connector clockwise with light finger pressure. If battery cable rotates, go to next step. If battery cable does not rotate, go to step 11 .
10. Using an INCH lb. torque wrench, record torque value while loosening positive battery cable bolt. If torque is equal to or greater than 89 INCH lbs. (10 N.m), go to step 12 . If torque is below 89 INCH lbs. (10 N.m), go to next step.
11. Disconnect positive battery cable and go to step 13 .
12. Disconnect positive battery cable. Inspect battery and cable terminals for corrosion and defects. Repair as necessary. Go to next step.
13. Clean and wire brush lead face of both battery terminals and metal contact surfaces on both cable connectors. Remove bolts from both battery cable connectors and inspect for corrosion and defects. Repair or replace as necessary. If battery and cables terminals are clean and in good condition, go to next step.
14. Connect positive battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
15. Connect negative battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m). Go to next step.
16. Ensure all electrical loads are off. Follow manufacturers instructions and install Battery Tester (J-42000) to vehicle battery. Follow any instructions displayed on battery tester. If battery tester passed battery, go to next step. If battery tester did not pass battery, go to step 18 .
17. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Battery is okay.
18. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty purposes. Replace battery.
19. Replace battery.

SELF-DIAGNOSTIC SYSTEM

Note. Diagnostic trouble code tests are written specifically for use with GM Tech I or Tech II scan tools. Generic scan tool can be used but may have limited functions.

Alero & Grand Am

1. Perform battery inspection test. See «BATTERY TESTING & INSPECTION»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system__battery-testing-inspection) under ON-VEHICLE TESTING. Go to next step.
2. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. If scan tool powers up, go to next step. If scan tool does not power up, repair as necessary. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
3. Turn ignition on. Attempt communication with each module on the class 2 serial data circuit. If scan tool communicates with all modules, go to next step. If scan tool does not communicate with any module, repair communications concern. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
4. Using scan tool, select DISPLAY DTCs function for each module. Record all DTCs displayed, DTC status and module which set the DTC. If scan tool displayed any DTCs, go to next step. If scan tool does not display any DTCs, repair starting system by symptom. See «SYMPTOM INDEX»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) table under SYSTEM TESTS.
5. If scan tool displays DTCs which begin with "U", perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. If scan tool does not display DTCs which begin with "U", go to next step.
6. If scan tool displays DTC B1000 or B1001, perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. If scan tool does not display DTC B1000 or B1001, perform appropriate test in accordance with DTCs retrieved. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

Malibu

1. Perform battery inspection test. See «BATTERY TESTING & INSPECTION»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system__battery-testing-inspection) under ON-VEHICLE TESTING. Go to next step.
2. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. If scan tool powers up, go to next step. If scan tool does not power up, repair as necessary. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
3. Turn ignition on. Attempt communication with each module on the class 2 serial data circuit. If scan tool communicates with all modules, go to next step. If scan tool does not communicate with any module, repair communications concern. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
4. Using scan tool, select DISPLAY DTCs function for each module. Record all DTCs displayed, DTC status and module which set the DTC. If scan tool displayed any DTCs, go to next step. If scan tool does not display any DTCs, repair starting system by symptom. See «SYMPTOM INDEX»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) table under SYSTEM TESTS.
5. If scan tool displays DTCs which begin with "U", perform appropriate test. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT. If scan tool does not display DTCs which begin with "U", perform appropriate test in accordance with DTCs retrieved. See appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.

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.

SYMPTOM INDEX

A/T

1. If engine electrical diagnostic system check was not performed, go to «ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under SELF-DIAGNOSTIC SYSTEM. If engine electrical diagnostic system check was performed, go to next step.
2. Turn ignition switch to START position. If theft indicator light is flashing, repair anti-theft system as necessary. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. If theft indicator light is not flashing, go to next step.
3. Turn ignition switch to START position. If starter solenoid clicks, go to «TEST B: ENGINE DOES NOT CRANK, SOLENOID CLICKS»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system__test-b-engine-does-not-crank) . If starter solenoid does not click, go to next step.
4. If engine cranks and runs normally, check electrical wiring system for intermittent and/or poor connections. If engine does not crank and run normally, go to next step.
5. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. Place transmission in Park or Neutral. Using scan tool, observe TR SW parameter in PCM data list. If scan tool indicates PARK or NEUTRAL, go to next step. If scan tool does not indicate PARK or NEUTRAL, repair transmission related concern. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS.
6. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and Purple wire terminal at starter solenoid. If voltage drop is less than 0.5 volts, go to step 11 . If voltage drop is greater than 0.5 volts, go to next step.
7. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and terminal "E" (Purple wire) at PNP switch connector C1. If voltage drop is less than 0.5 volts, go to next step. If voltage drop is greater than 0.5 volts, go to step 9 .
8. Repair open or high resistance in Purple wire between PNP switch and starter. After repairs, go to step 17 .
9. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and terminal "G" (Yellow wire) at PNP switch connector C1. If voltage drop is less than 0.5 volts, go to step 12 . If voltage drop is greater than 0.5 volts, go to next step.
10. Check for open or high resistance in Yellow wire between terminal "B" at ignition switch connector C1 and terminal "G" at PNP switch connector C1. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 13 .
11. Check for poor connection at starter solenoid. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 14 .
12. Check for poor connection at PNP switch. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 15 .
13. Check for poor connection at ignition switch. If problem exists, repair as necessary and go to step 17 . If problem does not exist, go to step 16 .
14. Replace starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under REMOVAL & INSTALLATION. After repairs, go to step 17 .
15. Replace PNP switch. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. After repairs, go to step 17 .
16. Replace ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. After repairs, go to next step.
17. Operate system and verify repair. If condition is corrected, system is okay. If not, go to step 2 .

M/T

1. If engine electrical diagnostic system check was not performed, go to «ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under SELF-DIAGNOSTIC SYSTEM. If engine electrical diagnostic system check was performed, go to next step.
2. Turn ignition switch to START position. If theft indicator light is flashing, repair anti-theft system as necessary. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. If theft indicator light is not flashing, go to next step.
3. Turn ignition switch to START position. If starter solenoid clicks, go to «TEST B: ENGINE DOES NOT CRANK, SOLENOID CLICKS»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system__test-b-engine-does-not-crank) . If starter solenoid does not click, go to next step.
4. If engine cranks and runs normally, check electrical wiring system for intermittent and/or poor connections. If engine does not crank and run normally, go to next step.
5. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and Purple wire terminal at starter solenoid. If voltage drop is less than 0.5 volts, go to step 10 . If voltage drop is greater than 0.5 volts, go to next step.
6. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and terminal "B" (Purple wire) at Clutch Pedal Position (CPP) switch connector. If voltage drop is less than 0.5 volts, go to next step. If voltage drop is greater than 0.5 volts, go to step 8 .
7. Repair open or high resistance in Purple wire between CPP switch and starter. After repairs, go to step 16 .
8. Turn ignition switch to START position. Using a DVOM, measure voltage drop between positive battery terminal and terminal "A" (Yellow wire) at CPP switch connector. If voltage drop is less than 0.5 volts, go to step 11 . If voltage drop is greater than 0.5 volts, go to next step.
9. Check for open or high resistance in Yellow wire between terminal "B" at ignition switch connector C1 and terminal "A" at CPP switch connector. If problem exists, repair as necessary and go to step 16 . If problem does not exist, go to step 12 .
10. Check for poor connection at starter solenoid. If problem exists, repair as necessary and go to step 16 . If problem does not exist, go to step 13 .
11. Check for poor connection at CPP switch. If problem exists, repair as necessary and go to step 16 . If problem does not exist, go to step 14 .
12. Check for poor connection at ignition switch. If problem exists, repair as necessary and go to step 16 . If problem does not exist, go to step 15 .
13. Replace starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under REMOVAL & INSTALLATION. After repairs, go to step 16 .
14. Replace CPP switch. After repairs, go to step 16 .
15. Replace ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. After repairs, go to next step.
16. Operate system and verify repair. If condition is corrected, system is okay. If not, go to step 2 .

TEST B: ENGINE DOES NOT CRANK, SOLENOID CLICKS

1. If diagnostic system check was not performed, go to «ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under SELF-DIAGNOSTIC SYSTEM. If diagnostic system check was performed, go to next step.
2. Turn ignition to START position. If starter solenoid clicks, go to next step. If starter solenoid does not click, see «TEST A: STARTER SOLENOID DOES NOT CLICK»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) .
3. Inspect engine and belt drive system for mechanical binding. If engine moves freely, go to next step. If engine does not move freely, repair as necessary.
4. Check for an open or high resistance in positive battery cable between battery and starter. See «WIRING DIAGRAMS»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) . If problem exists, repair as necessary and go to step 8 . If problem does not exist, go to next step.
5. Check for open or high resistance in negative battery cable between battery and ground point. If problem exists, repair as necessary and go to step 8 . If problem does not exist, go to next step.
6. Check for poor connections at starter motor. If problem exists, repair as necessary and go to step 8 . If problem does not exist, go to next step.
7. Replace starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under REMOVAL & INSTALLATION. When repair is complete, go to next step.
8. Operate system and verify repair. If condition is corrected, system is okay. If not, go to step 2 .

TEST C: ENGINE CRANKS SLOWLY

1. Ensure battery is in good condition. See «BATTERY TESTING & INSPECTION»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system__battery-testing-inspection) under ON-VEHICLE TESTING. If problem exists, repair as necessary. If problem does not exist, go to next step.
2. Inspect wiring system for damage or poor connections at starter motor, starter solenoid, battery and all grounds. If problem exits, repair as necessary. If problem does not exist, go to next step.
3. Inspect engine and belt drive system for mechanical binding. If engine moves freely, go to next step. If engine does not move freely, repair as necessary.
4. Replace starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under REMOVAL & INSTALLATION.

TEST D: STARTER NOISE DIAGNOSIS

1. If diagnostic system check was not performed, go to «ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under SELF-DIAGNOSTIC SYSTEM. If diagnostic system check was performed, go to next step.
2. Start engine. If starter operates normally, check wiring system for intermittent or poor connection condition. If starter does not operate normally, go to next step.
3. Start engine while listening to starter motor turn. If there is a loud "whoop", go to step 6 . If there is not a loud "whoop", go to next step.
4. If there is a "rumble", a "growl", or a "knock" as starter is slowing down to a stop after starting engine, go to step 7 . If there is not a "rumble", a "growl", or a "knock" as starter is slowing down to a stop after starting engine, go to next step.
5. If there is a high pitched "whine" after engine cranks and starts normally, go to step 8 . If there is not a high pitched "whine" after engine cranks and starts normally, go to step 7 .
6. Inspect flywheel ring gear for chipped, missing, or milled gear teeth and/or if flywheel is damaged or bent. If problem exists, go to step 9 . If problem does not exist, go to step 10 .
7. Remove starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Inspect starter motor bushings and clutch gear. If problem exists, go to step 10 . If problem does not exist, go to step 9 .
8. Shim starter motor away from flywheel by adding shims between engine block and starter motor. After repairs, go to step 11 .
9. Replace flywheel. After repairs, go to step 11 .
10. Replace starter motor. See «STARTER»(/chevrolet/malibu/v-2000-2003/remont/starter/#starting-system) . When repair is complete, go to step 11 .
11. Retest system to verify repair. If condition is corrected, system is okay. If condition is not corrected, go to step 3 .

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 (2.4L)

Disconnect negative battery cable. Remove air inlet duct-to-throttle body. Remove top starter bolt. Raise and support vehicle. Remove lower closeout panel. Remove lower starter bolt. Position engine wiring harness aside. Disconnect starter solenoid wiring. 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. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

Removal (3.1L)

Disconnect negative battery cable. Raise and support vehicle. Remove lower closeout panel. Remove starter mounting bolts. Disconnect starter solenoid wiring. Remove shims and note arrangement for reassembly (if equipped). Remove starter assembly.

Removal (3.4L)

Disconnect negative battery cable. Raise and support vehicle. Remove flywheel cover(s). Disconnect starter solenoid wiring. Remove starter mounting bolts. Remove shims and note arrangement for reassembly (if equipped). Remove starter assembly.

Installation (3.1L & 3.4L)

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. Ensure shims are installed in original location (if equipped). To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

OVERHAUL

Note. Starter assemblies are not serviceable and should be replaced as complete units.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• COMPONENT LOCATIONS
• SELF-DIAGNOSTIC SYSTEM
• BATTERY SPECIFICATIONS
• BATTERY TESTING & INSPECTION
• B
• C
• D
• TORQUE SPECIFICATIONS