Cobalt 2006-2008, G5 2007

Starter

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the charge air cooler pump:
    1. Drain the charge air cooling system.
    2.  
    3. Compress the auxiliary water pump inlet hose clamp at the charge air cooler pump.
    4.  
    5. Remove the auxiliary water pump inlet hose from the charge air cooler pump.
    6.  
    7. Compress the auxiliary water pump outlet hose clamp at the charge air cooler pump.

      Click image to see an enlarged view

      Fig. Auxiliary coolant pump-2.0L engine



      Click image to see an enlarged view

      Fig. Charge air coolant pump-2.0L engine

    8.  
    9. Remove the auxiliary water pump outlet hose from the charge air cooler pump.
    10.  
    11. Disconnect the charge air cooler pump electrical connector.
    12.  
    13. Remove the charge air cooler pump mounting clamp bolts.
    14.  
    15. Remove the charge air cooler pump.
    16.  

  8.  
  9. Remove or disconnect the following:

    The starter solenoid terminal nut (6).
     
    The positive battery cable terminal (5) and the starter solenoid terminal (4) from the starter
     
    The starter solenoid "S" terminal nut
     
    The engine harness terminal from the starter
     
    The starter bolts
     
    The starter

    Click image to see an enlarged view

    Fig. Electrical connections illustrated for starter removal-2.0L Engine

     

  10.  

To install:

  1. Position the starter to the engine.
  2.  
  3. Install the starter bolts and tighten to 37 ft. lbs. (50 Nm).
  4.  
  5. Install or connect the following:
    NOTE
    Ensure that the anti-rotational tab on the positive battery cable terminal is correctly located into the indexing slot.



    The engine harness terminal to the starter
     
    The starter solenoid "S" terminal nut and tighten to 27 inch lbs. (3 Nm).
     
    The starter solenoid terminal and the positive battery cable terminal to the starter
     



    The starter solenoid terminal nut and tighten to 97 inch lbs. (11 Nm)
     

  6.  
  7. Install the charge air cooler pump:
    1. Install the mounting clamp bolts to the charge air cooler pump. Tighten the bolts to 88 inch lbs. (10 Nm).
    2.  
    3. Connect the charge air cooler pump electrical connector.
    4.  
    5. Compress the auxiliary water pump inlet hose clamp to secure the hose.
    6.  
    7. Install the auxiliary water pump inlet hose to the charge air cooler pump.
    8.  
    9. Compress the auxiliary water pump outlet hose clamp to secure the hose.
    10.  
    11. Install the auxiliary water pump outlet hose to the charge air cooler pump.
    12.  

  8.  
  9. Lower the vehicle.
  10.  
  11. Fill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  

2.2L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove or disconnect the following:

    The starter solenoid terminal nut (5)
     
    The positive battery cable terminal (4) from the starter
     
    The starter solenoid wire terminal (3) from the starter
     
    The starter solenoid "S" terminal nut (2)
     
    The engine harness terminal (1) from the starter
     
    The starter bolts
     
    The starter

    Click image to see an enlarged view

    Fig. Electrical connections illustrated for starter removal-2.2L & 2.4L Engines

     

  8.  

To install:

  1. Position the starter to the engine.
  2.  
  3. Install or connect the following:
    NOTE
    Ensure that the anti-rotational tab is correctly located into the indexing slot.



    The starter bolts and tighten to 30 ft. lbs. (40 Nm).
     
    The engine harness terminal (1) to the starter
     
    The starter solenoid "S" terminal nut (2) and tighten to 27 inch lbs. (3 Nm)
     
    The starter solenoid wire terminal (3) to the starter
     
    The positive battery cable terminal (4) to the starter
     



    The starter solenoid terminal nut (5) and tighten to 13 ft. lbs. (17 Nm)
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  

Testing & Troubleshooting



Inspect for aftermarket devices which could affect the operation of the starting and charging systems. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause a fault symptom.

The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch, connection wires and the battery cables. When the ignition key is turned to the start position, current flows and energizes the starter motor solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear. The contacts close and the starter motor cranks the engine. In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage. Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held in place. If damaged, replace the starter drive.

If the starter is not turning over the engine, check that the wire connections are fastened securely to the starter solenoid and that battery voltage (12 volts) is supplied to the starter.

The Engine Control Module (ECM)/Powertrain Control Module (PCM) controls engine cranking based on a power mode input and the status of the clutch start switch (manual transaxle) or the Park/Neutral Position (PNP) switch (automatic transaxle). With the transaxle in Park/Neutral or the clutch depressed, voltage at the ECM/PCM PNP/clutch start switch signal circuit is high. This indicates to the ECM/PCM that conditions are acceptable for cranking. When a power mode crank request is seen, the ECM/PCM grounds the starter relay coil control circuit. This energizes the coil side of the relay, which pulls the switch side of the relay closed, applying voltage to the starter S-terminal and engaging the starter solenoid.

A misadjusted PNP switch or clutch start switch may result in a starter solenoid that will not engage or click.

 
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