GM Cavalier/Sunfire 1995-2000 Repair Guide

Starter

Print

TESTING



Voltage Drop Test

The battery must be in good condition and fully charged prior to performing this test.

  1. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  2.  
  3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  4.  
  5. Turn the ignition key to the START position and note the voltage on the meter.
  6.  
  7. If voltage reads 0.5 volte or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  8.  
  9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  10.  
  11. Turn the ignition key to the START position and note the voltage on the meter.
  12.  
  13. If voltage reads 0.5 volte or more, there is high resistance in the starter. Repair or replace the starter as necessary.
  14.  

Many automotive parte stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

REMOVAL & INSTALLATION



2.2L (VIN 4) Engine

See Figures 1 through 9



Click image to see an enlarged view

Fig. Fig. 1: Removal and installation of the starter-2.2L engine shown



Click image to see an enlarged view

Fig. Fig. 2: Remove the starter electrical connections from the back of the starter



Click image to see an enlarged view

Fig. Fig. 3: Remove the three bell-housing cover retaining bolts and ...



Click image to see an enlarged view

Fig. Fig. 4: ... remove the bell-housing cover



Click image to see an enlarged view

Fig. Fig. 5: Remove the starter support brace-to-engine bolt



Click image to see an enlarged view

Fig. Fig. 6: The starter is retained by two bolts



Click image to see an enlarged view

Fig. Fig. 7: Remove the bolts and ...



Click image to see an enlarged view

Fig. Fig. 8: ... remove the starter from the engine



Click image to see an enlarged view

Fig. Fig. 9: Note that the starter bolts are two different lengths, the longer one goes on the inside

  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the electrical connections from the back of the starter.
  6.  
  7. Remove the bell-housing cover.
  8.  
  9. Remove the starter support bracket bolt from the engine block.
  10.  
  11. Unfasten the starter motor-to-engine bolts, then carefully lower the starter.
  12.  
  13. Remove the nuts/bolts that hold the starter support bracket to the starter.
  14.  

To install:
  1. Transfer the starter support bracket to the new starter if the starter is being replaced.
  2.  
  3. Raise the starter into position and secure the starter using the starter motor-to-engine bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  4.  
  5. Install the starter support bracket-to-engine bolt to 24 ft. lbs. (32 Nm).
  6.  
  7. Install the bell-housing cover.
  8.  
  9. Install the starter electrical connections on the back of the starter. Tighten the S terminal to 22 inch lbs. (2.5 Nm) and the battery terminal to 106 inch lbs. (12 Nm).
  10.  
  11. Carefully lower the vehicle, then connect the negative battery cable.
  12.  

2.3L (VIN D) and 2.4L (VIN T) Engines

See Figure 10



Click image to see an enlarged view

Fig. Fig. 10: When installing the starter, tighten the mounting bolts to 66 ft. lbs. (90 Nm) on the 2.3L and 2.4L engines

  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Detach the air inlet duct from the throttle body.
  4.  
  5. Remove the top starter bolt.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the lower starter retaining bolt.
  10.  
  11. If necessary, position the engine wiring harness aside.
  12.  
  13. Position the starter to enable accese to the solenoid wiring, then detach the wiring.
  14.  
  15. Remove the starter from the vehicle.
  16.  

To install:
  1. Raise the starter to the vehicle, then attach the wiring.
  2.  
  3. Position the starter, then secure using the lower starter bolt. Tighten to 66 ft. lbs. (90 Nm)
  4.  
  5. If moved, reposition the engine wiring harness.
  6.  
  7. Carefully lower the vehicle.
  8.  
  9. Install the top starter bolt, then tighten to 66 ft. lbs. (90 Nm).
  10.  
  11. Fasten the air inlet duct to the throttle body.
  12.  
  13. Connect the negative battery cable.
  14.  

SOLENOID REPLACEMENT



See Figures 11 and 12



Click image to see an enlarged view

Fig. Fig. 11: Remove the nut attaching the solenoid cable



Click image to see an enlarged view

Fig. Fig. 12: Starter solenoid components

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter motor from the vehicle and place on a clean work surface.
  4.  
  5. Disconnect the solenoid-to-starter lead wire.
  6.  
  7. Remove the solenoid mounting bolte and slide out the solenoid. Pull out the solenoid torsion spring, if so equipped. On some models, it may be necessary to remove the starter assembly through bolte from the yoke to remove the solenoid.
  8.  
  9. If equipped with shime between the solenoid and starter, remove and place aside.
  10.  

To install:
  1. Install the solenoid with any adjustment shims.
  2.  
  3. Torque the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the starter-to-solenoid electrical lead.
  6.  
  7. Install the starter through-bolts if removed.
  8.  
  9. Install the starter motor.
  10.  
  11. Check for proper operation.
  12.  

 
label.common.footer.alt.autozoneLogo