Starter Pontiac Sunbird II

DESCRIPTION

Four types or sizes of 12-volt starting motors are used, all are equipped with an enclosed solenoid, shift lever, and overrunning clutch. The starting motor circuits differ depending upon the load and speed requirements.

The 5MT series starting motor differs from the 10MT series in that the 5MT has its field coils permanently mounted in the frame and the 10MT has an optional center bearing. The 5MT and 10MT starting motors are used on gasoline engines.

The 15MT/GR and ALU/GR gear reduction starting motor is used on all V6 and most V8 diesel engines. The 27MT starting motor is primarily used on all 5.7L diesel V8 engines. The 27MT starters have a longer shaft and a center bearing to support the longer shaft.

OPERATION

In the basic starting circuit, the solenoid windings are energized when the switch is closed. This causes the plunger and shift lever to move the drive pinion into the flywheel ring gear. The solenoid main contact closes, causing cranking of the engine to occur.

When the engine starts, pinion overrunning clutch prevents armature damage due to excessive speed until the starting switch is opened. This permits the return spring to disengage the pinion from the flywheel.

TROUBLE SHOOTING

Note. See the TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.

SOLENOID WINDINGS TEST

Note. Tests are performed on the solenoid with the motor leads disconnected to prevent overheating. Complete the tests in a minimum of time to prevent further overheating.

Pull-In Windings

1. Connect an ammeter in series with a 12 volt battery and the switch "S" terminal on the solenoid. (Scheme 1) Connect a voltmeter between the solenoid "S" terminal and ground. Connect a carbon pile across the battery.
2. Adjust the voltage to 10 volts and note the ammeter reading. It should be 14.5-16.5 amps for all starters.

Pull-In & Hold-In Windings

To check both windings, connect the test equipment (Scheme 1) Ground the "M" (motor) terminal of the solenoid. Adjust the voltage to 10 volts and note the ammeter reading. If the ammeter reading is 41-47 amps, the starter solenoid is good.

Test Results

If the current draw readings are above specifications, a short or ground is indicated in the windings of the solenoid. Refer to the DELCO-REMY STARTER NO-LOAD TEST SPECIFICATIONS table. Low current draw readings indicate excessive resistance. No readings indicate an open circuit. Check the connections, if necessary, replace the solenoid.

Solenoid Winding Test Connections The switch must be open when making the connections. Scheme 1

Note. Make all connections and disconnections of equipment with the switch in the open position.

Scheme 2

1. To perform the test, connect the test equipment to the starter (Scheme 2) Close the switch and compare the RPM, amperage, and voltage readings with the specifications. Refer to the «DELCO-REMY STARTER NO-LOAD TEST SPECIFICATIONS»(/pontiac/sunbird/ii-1981-1988/remont/starter/#starter) table. (Scheme 2): Starter No-Load Connections The switch must be open when making the connections. CAUTION: DO NOT apply voltage greater than specified; excessive voltage may cause the armature to throw its windings because of the excessive speed.
2. If the current draw and RPM meet specifications, the condition of starter motor is normal. If the test indicates low free speed and high current draw, the problem could be too much friction resulting from tight, dirty or worn bearings, shorted armature, or grounded armature or fields.
3. Failure to operate with high current draw indicates a direct ground in the terminal fields or frozen bearings. Failure to operate with no current draw indicates an open field circuit, open armature coils, or broken brush springs.
4. Low no load RPM and low current draw indicates high internal resistance due to poor connections, defective leads, or a dirty commutator. High free speed and high current draw indicates shorted fields.

1.8L 4-CYL. Vin Code O (Man. Trans.)

1. Disconnect negative battery cable. Remove upper starter-to-engine block bolt.
2. Raise and support vehicle. Remove rear starter bracket.
3. Remove lower starter-to-engine block bolt.
4. Disconnect solenoid wires. Remove starter.

1.8L 4-Cyl. Vin Code O (Auto. Trans.)

1. Disconnect negative battery cable. Remove air cleaner assembly.
2. Remove lower starter-to-engine block bolt. Remove rear starter bracket.
3. Disconnect solenoid wires. Remove starter-to-engine block bolts.
4. Raise and support vehicle. Disconnect speedometer cable.
5. Push shift cable up and guide starter down between stabilizer and engine. It may be necessary to pry engine forward.

1.8L 4-Cyl. Vin Code J

1. Disconnect negative battery cable. Remove intake manifold support bracket.
2. Disconnect wiring to ignition coil and manifold air temperature sensor on intake manifold.
3. Remove upper starter bolt. Remove intake manifold-to-engine harness brackets bolts.
4. Raise and support vehicle. Remove transmission strut. Remove fuel line support bracket.
5. Remove rear starter bracket. DO NOT bend turbo oil feed pipe. Disconnect solenoid wiring and remove starter.

2.0L 4-CYL.

1. Disconnect negative battery cable. Remove wires from solenoid.
2. Remove rear starter support bracket.
3. Remove A/C compressor support rod (if equipped).
4. Remove starter mounting bolts. Remove starter.

Scheme 3

1. Disconnect negative battery cable(s). Install engine support fixture.
2. Ensure bolt securing chain to cylinder head is tightened to 20 ft. lbs. (27 N.m). (Scheme 3) (Scheme 3): Installing Engine Support Fixture Front wheel drive with 4.3L diesel only.
3. Raise and support vehicle. Remove left and center engine mount stud nuts.
4. Remove rack and pinion stub shaft-to-intermediate shaft pinch bolt. Disconnect shaft from steering gear.
5. Remove 2 front cradle mount bolts. Lower cradle enough to gain access to flywheel cover bolts.
6. Remove flywheel cover. Remove starter shield. Disconnect solenoid wires.
7. Remove starter mounting bolts. Remove starter.

All Other Engines

1. Disconnect negative battery cable. Raise and support vehicle.
2. Remove starter brackets or shields that may interfere with removal.
3. On "A" and "X" series, remove dust cover bolts and pull dust cover back.
4. On all series, remove starter mounting bolts. Lower starter.
5. Disconnect solenoid wires. Remove starter.

BENCH TESTS

Note. The following tests are made following removal or partial disassembly of the starter.

ARMATURE

1. Test the armature for shorted coils with a growler. Check for grounded coils with a 110 volt test lamp. Place one test lead on the armature shaft and the other test lead on the commutator. The lamp should not light. If the lamp lights, the armature is grounded and should be replaced.
2. Inspect the commutator. If the commutator is rough, worn, or has protruding insulation, turn the commutator in a lathe. DO NOT turn to less than 1.48" (37.6 mm) diameter for ALU/GR and 1.65" (41.9 mm) diameter for all others. Sand the commutator lightly with 240 grit emery paper and carefully clean out the slots.

SERIES COIL OPEN TEST

Using a test lamp, place one lead on the series coil terminal and other lead on the insulated brush. If the lamp fails to light, the series coil is open and requires repair or replacement. Repeat the test for each insulated brush to check it and its coil continuity.

SHUNT COIL OPEN TEST

Using test lamp, place one lead on shunt coil terminal and other lead to one ground brush holder. Repeat test for other ground terminal. If lamp fails to light on either test, field coil is open and must be repaired or replaced.

SERIES & SHUNT COIL GROUND TEST

Separate series and shunt coil strap terminals, DO NOT let terminals contact case or ground during test. Using test lamp place one lead on the grounded brush holder and the other lead to either insulated brush holder. If lamp lights series coil is grounded and must be repaired or replaced.

BRUSHES, SPRINGS & HOLDERS

Replace the brushes if worn to 1/2 of the original length, oil-soaked, or pitted. Check the brush spring tension and replace the springs if weak or distorted. Deformed or bent brush holders can be replaced by service units.

OVERRUNNING CLUTCH CHECK

The clutch pinion should turn freely in one direction only. Check the pinion teeth for chipped, cracked, or excessive wear. Chipped teeth may indicate a defective ring gear.

PINION CLEARANCE CHECK

1. Disconnect the motor field coil at the solenoid "M" terminal and insulate the field connector. Connect a 12 volt battery positive lead to the solenoid terminal "S" and the other to a ground. Touch a jumper lead from the solenoid "M" terminal to the starter frame, shifting the pinion into the cranking position.
2. Push the pinion away from the stop retainer as far as possible. Using a feeler gauge, check for.010-.140" (.25-3.6 mm) clearance between the pinion and retainer. (Scheme 4)

Checking Pinion End Play. Scheme 4

Note. The pinion clearance is not adjustable. If the clearance is not within specifications, the motor must be disassembled and checked for defects.

ALU/GR Models

1. Remove nut from field coil connector and remove 2 solenoid switch mounting screws. Remove solenoid by pulling upward and forward, remove shims if equipped. Remove field frame and armature from center housing.
2. Pry back brush spring so that each brush can be back away from armature about 1/4" (6.3 mm). Release spring to hold brushes in backed out position. Remove armature from field frame and brush holder.
3. Remove shaft cover on center housing and remove C-shaped washer and plate. Remove 2 center housing screws, remove center housing and thrust washer shim(s). Remove reduction gear, spring holder and 2 lever springs. Using 5/8" (16 mm) deep socket, drive snap ring retainer back and remove snap ring.

5MT & 10MT Models

1. Remove the field coil connector and solenoid housing mounting screws from the solenoid. After rotating the solenoid 90°, remove solenoid and plunger return spring.
2. Remove the 2 through bolts, Remove commutator end frame. Remove the plunger/shift lever assembly and armature assembly with the overrunning clutch, from the drive end housing. Remove the thrust washer or collar from the armature shaft. Slide a 5/8" (16 mm.) deep socket over the shaft against the retainer as a driving tool.
3. Tap the tool to move the retainer off the snap ring. Remove the snap ring from the groove in the shaft. If the snap ring is distorted, it must be replaced upon assembly. Remove the retainer and clutch assembly from the armature shaft.

Note. On the 27MT models, the armature remains in the drive end frame. The shift lever and plunger may be disassembled by removing the roll pin.

15MT/GR & 27MT Models

1. Remove screw from field coil connector and solenoid mounting screws. Rotate solenoid 90° and remove solenoid and plunger return spring. Remove 2 through bolts and remove the plunger/shift lever assembly and armature assembly with the overrunning clutch from the drive end housing. Remove the thrust washer or collar from the armature shaft.
2. Slide a 5/8" (16 mm.) deep socket over the shaft against the retainer as a driving tool. Tap the tool to move the retainer off the snap ring. Remove the snap ring from the groove in the shaft. If the snap ring is distorted, it must be replaced upon assembly. Remove the retainer and clutch assembly from the armature shaft (remove the insulator on the 27MT models).
3. On the 15MT/GR models, remove the field frame assembly from the drive gear housing. Remove the gear housing bolts and separate the gear housing from the drive housing. Remove the gear and washer from the drive shaft.
4. On the 27MT models, remove the shift lever bolt from the drive gear housing. Remove the center bearing screws. Remove the drive gear housing from the armature shaft. The shift lever and plunger will fall away from the starter clutch. Remove the fiber washer and center bearing.

Note. The roller type overrunning clutches are designed to be serviced as a complete unit ( DO NOT disassemble), if necessary, replace the overrunning clutch.

CLEANING

Clean all the parts by wiping with clean cloths. DO NOT clean the armature, field coils, or drive assembly in any type of grease dissolving solvent (it will damage the insulation and wash the lubricant out of the drive assembly).

All Except ALU/GR Models

Inspect the armature shaft bearing surfaces and check for wear by noting the side play with the shaft installed in the bushings. To replace drive end housing bearing use tube or collar that just fits inside the housing and press bearing out. To install, using same tool press bearing until .015" below casting surface. If the bushing is worn, replace the commutator end plate assembly.

ALU/GR Drive End Housing Bearing

Using a 15/16" (24 mm.) socket inside the housing, push the bearing out toward the armature side. Press the new bearing into the housing using 1-1/8" (28 mm.) socket from the opposite side until the bearing is flush with the housing. If the housing is worn, replace the drive end housing assembly.

ALU/GR Armature Bearings

Using Holding Fixture (J-22912-01), press bearing off armature shaft. To install armature commutator end bearing, hold armature in holding fixture and drive bearing on with 1/2" (12 mm) socket. To install armature drive end bearing, use holding fixture and drive bearing on shaft using 3/4" (21 mm.) deep socket.

Scheme 5

Scheme 6

1. Lubricate the drive end of the armature shaft with silicone lubricant. Install the center bearing (27MT only) with the bearing facing the armature winding. Install the fiber washer on the armature shaft.
2. Slide the clutch assembly onto the armature shaft with the pinion away from the armature. Slide the retainer onto the shaft with the cupped side facing the shaft end. Install the snap ring into the groove on the shaft. Install the thrust washer. (Scheme 5): Exploded View of Delco-Remy 27MT Starter Motor
3. Position the retainer and the thrust washer with the snap ring located between them. Using two pliers, grip the retainer and thrust washer; then, squeeze it until the snap ring is forced into the retainer and is held securely in the armature shaft groove.
4. Lubricate the drive gear housing bushing. Engage the shift lever yoke with the clutch and slide the complete assembly into the drive gear housing.
5. On 15MT/GR models, the shift lever may be installed in the gear housing first. Install the center bearing screws (27MT only) and the shift lever pivot bolt. Install drive housing, tighten though bolts and install the solenoid assembly on the drive gear housing. Test starter and install. (Scheme 6): Exploded View of Delco-Remy 5MT Starter Motor Assembly The 10MT model starter is similar.
6. Apply sealer to the solenoid flange where the field frame contacts it. Position the field frame against the drive gear housing on the alignment pin, being careful not to damage the brushes. Lubricate the commutator end frame bushing with lubricant.
7. Install the washer on the armature shaft and slide the end frame onto the shaft. On the 27MT model starter, install the insulator and the end frame onto the shaft. Install the through bolts and tighten. Connect the field coil connector to the solenoid "M" terminal. Make sure the through bolts pass through the bolt holes in the insulator. Check the pinion clearance.

1. Lubricate bearing surfaces, splines, nylon lever holders and both ends of lever with lubricant. Install lever assembly on the overrunning clutch and install pinion shaft and lever assembly into drive end housing.
2. Slide spring, drive pinion and snap ring retainer over shaft. While forcing drive pinion and retainer down against housing install ring into groove on pinion shaft. Using tool (J-22888) force snap ring retainer over snap ring.
3. Install 2 lever springs and spring holder into drive housing. Lubricate reduction gears and install gear and thrust washer shims onto pinion shaft. Install center housing to drive housing and install 2 attaching bolts. Install plate and C-washer on end of pinion shaft. Fill end cap with lubricant and install with 2 attaching screws.
4. Position field frame and brush holder assembly on center housing. Install brushes and allow brushes to seat against commutator bars. Install commutator end frame and install and tighten 2 brush holder screws.
5. Install solenoid switch and shims on drive housing, making sure the slot in plunger engages with top of levers. Connect field coil connector and test starter.

SPECIFICATIONS

DELCO-REMY STARTER NO-LOAD TEST SPECIFICATIONS

See also:
• TROUBLE SHOOTING - BASIC PROCEDURES
• DELCO-REMY STARTER NO-LOAD TEST SPECIFICATIONS