Starting System: Removal & Installation GMC Savana H2500

Removal

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

1. Remove the electrical center cover. Locate the relay. See «FUSES & CIRCUIT BREAKERS»(ref-167565) 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 1) 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 1

Installation

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

STARTER MOTOR REPLACEMENT (4.3L)

1. Disconnect the battery negative cable. Raise the vehicle.
2. Remove the starter motor brackets and shields, if equipped. (Scheme 2)
3. Disconnect the wires from the starter solenoid. (Scheme 3)
4. Remove the bolts and the shims, if present, from the starter motor. (Scheme 4) Remove the starter motor from the engine.

Scheme 2

Scheme 3

Scheme 4

1. Install the starter motor to the engine. (Scheme 4) Install the bolts and the shims, if present, to the starter motor. Tighten the bolts to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).
2. Connect the wires to the starter solenoid. (Scheme 3) Tighten the starter lead nut to the solenoid to specification. Tighten the starter solenoid wires to the solenoid to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).
3. Install the starter motor brackets and shields. (Scheme 2)
4. Connect the battery negative cable. Tighten to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).

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

1. Disconnect the negative battery cable. Raise and suitably support the vehicle.
2. Remove the right transmission cover bolt. (Scheme 5)
3. Remove the starter bolts. (Scheme 6) Disconnect the oil level sensor electrical connector. Slide the starter forward until the starter clears the transmission.
4. Remove the starter solenoid nut. (Scheme 7) 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 8)
7. If necessary, remove the starter shield. (Scheme 9)

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. If necessary, install the starter shield. (Scheme 9)
2. Snap the transmission cover to the starter. (Scheme 8)
3. Install the positive cable to the starter stud. (Scheme 7) Install the starter lead nut. Tighten the starter lead nut to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).
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»(ref-168700-S00852492712004111600000).
5. Slide the starter rearward. (Scheme 6) Install the starter bolts. Tighten the starter bolts to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).
6. Connect the oil level sensor electrical connector.
7. Install the right transmission cover bolt. (Scheme 5) Tighten the transmission cover bolt to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).
8. Lower the vehicle. Connect the negative battery cable. Tighten to specification. See «FASTENER TIGHTENING SPECIFICATIONS»(ref-168700-S00852492712004111600000).

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.