GM Corsica/Beretta 1988-1996 Repair Guide

Starter

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TESTING



See Figure 1

  1. Make the connections as shown in the accompanying figure.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Starter no load test connections

  1. Close the switch and compare the RPM, current and voltage readings with the following values.

    2.0L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-11,900 rpm
     
    1990 2.2L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-11,900 rpm
     
    1991 2.2L engine: No load test @80 volts - 14-85 amps, RPM at drive pinion - 7,40-12,000 rpm
     
    1992 2.2L engine: No load test @80 volts - 45-75 amps, RPM at drive pinion - 6,000-11,000 rpm
     
    1993 2.2L engine: No load test @80 volts - 6-76 amps, RPM at drive pinion - 6,000-12,000 rpm
     
    1994-95 2.2L engine: No load test @80 volts - 45-75 amps, RPM at drive pinion - 6,000-11,000 rpm
     
    1996 2.2L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-12,000 rpm
     
    1990 2.3L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-11,900 rpm
     
    1991-93 2.3L engine: No load test @80 volts - 6-76 amps, RPM at drive pinion - 6,000-12,000 rpm
     
    1994 2.3L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-12,000 rpm
     
    2.8L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-11,900 rpm
     
    1990 3.1L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-11,900 rpm
     
    1991-95 3.1L engine: No load test @80 volts - 45-75 amps, RPM atdrive pinion - 6,000-11,000 rpm
     
    1996 3.1L engine: No load test @80 volts - 4-75 amps, RPM at drive pinion - 6,000-12,000 rpm
     

  2.  
  3. Rated current draw and no load speed indicates normal condition of the starter motor.
  4.  
  5. Low free speed and high current draw indicates:

    Too much friction. Tight, dirty, or worn bushings, bent armature shaft allowing armature to drag.
     
    Shorted armature. This can be further checked on a growler after disassembly.
     
    Grounded armature or fields. Check further after assembly.
     

  6.  
  7. Failure to operate with high current draw indicates:

    A direct ground in the terminal or fields.
     
    "Frozen" bearings.
     

  8.  
  9. Failure to operate with low or no current draw indicates:

    Open solenoid windings.
     
    Open field circuit. This can be checked after disassembly by inspecting internal connections and tracing the circuit with a test lamp.
     
    Open armature coils. Inspect the commutator for badly burned bar after disassembly.
     
    Broken brush springs, worn brushes, high insulation between the commutator bars of other causes which would prevent good contact between the brushes and commutator.
     

  10.  
  11. Low no-load speed and low current draw indicates:

    High internal resistance due to poor connections, defective leads, dirty commutator and causes listed under Step 6.
     

  12.  
  13. High free speed and high current drain usually indicate shorted fields. If shorted fields are suspected, replace the field and frame assembly. Also check for shorted armature using a growler.
  14.  

REMOVAL & INSTALLATION




CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

2.0L and 2.2L Engines

See Figure 2

1988 VEHICLES
  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Raise and support the car safely.
  4.  
  5. Remove the solenoid wires and the battery cable.
  6.  
  7. Remove the rear motor support bracket.
  8.  
  9. Remove the air conditioning compressor support rod (if so equipped).
  10.  
  11. Remove the two starter-to-engine bolts, and allow the starter to drop down. Note the location and number of any shims (if used). Remove the starter.
  12.  
  13. Installation is the reverse of removal. Torque the 2 mounting bolts to 26-37 ft. lbs. (30-4 Nm).
  14.  

1989-96 VEHICLES
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. For8995-96 vehicles equipped with manual transaxles, remove the bending brace.
  6.  
  7. Remove the solenoid wires and the battery cable from the starter.
  8.  
  9. If equipped, remove the wiring clamp from the support bracket.
  10.  
  11. Remove the support bracket-to-engine bolt.
  12.  
  13. Remove the 2 bolts from the starter motor.
  14.  
  15. Remove the starter motor and shims, if equipped.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the starter motor - 2.0L and 2.2L engines

To install:
  1. Position the shims, if used, then install the starter motor.
  2.  
  3. Install the 2 starter motor retaining bolts and tighten to 32 ft. lbs. (43 Nm).
  4.  
  5. Install the support bracket bolt to the engine and tighten to 24 ft. lbs. (32 Nm).
  6.  
  7. If equipped, install the wiring clamp to the support bracket. Tighten the bolt to806 inch lbs. (12 Nm).
  8.  
  9. Attach the starter motor wiring.
  10.  
  11. If removed, install the bending brace.
  12.  
  13. Carefully lower the vehicle, then connect the negative battery cable.
  14.  

2.3L Engine
1990 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Detach the electrical connector from the cooling fan.
  4.  
  5. Remove the cooling fan mounting bolts and remove the fan assembly.
  6.  

You can use a85mm socket with a 6 inch extension to remove the brace-to-starter bolt.

  1. Remove the intake manifold-to-engine brace bolts and remove the brace from the engine.
  2.  
  3. Remove the starter mounting bolts.
  4.  
  5. Carefully lift the starter away from the engine with the solenoid harness attached to it.
  6.  
  7. When the starter is clear, detach the solenoid harness connections and lift the starter up and out toward the front of the vehicle.
  8.  

To install:
  1. Attach the solenoid harness connections to the starter, while supporting the starter toward the mounting position.
  2.  
  3. Rotate the starter so the solenoid faces the engine at a slight angle to clear the bottom of the intake manifold.
  4.  
  5. Position the starter to the engine and install the mounting bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the intake manifold-to-engine brace and the attaching bolts.
  8.  
  9. Install the cooling fan and attaching bolts. Tighten bolts to 89 inch lbs. (10 Nm). Attach the cooling fan electrical connector.
  10.  
  11. Connect the negative battery cable, then crank the engine and check for proper starter operation.
  12.  

1991 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the serpentine drive belt.
  4.  
  5. Remove the coolant reservoir.
  6.  
  7. Unfasten the A/C rail line clip.
  8.  
  9. Remove the alternator, as outlined in this section.
  10.  
  11. Remove the dipstick, bolt and oil filler tube.
  12.  
  13. Remove the alternator bracket.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Remove the upper transaxle-to-starter mounting bolt.
  18.  
  19. Remove the oil filter.
  20.  
  21. Remove the lower starter mounting bolt.
  22.  
  23. Position the starter for access to the solenoid wiring.
  24.  
  25. Disconnect the electrical wiring.
  26.  
  27. Remove the starter from the vehicle, routing through the front of the engine between the intake manifold and engine block.
  28.  

To install:
  1. Install the starter by lowering it between the intake manifold and engine block.
  2.  
  3. Attach the starter electrical connectors.
  4.  
  5. Position the starter to the engine.
  6.  
  7. Install the starter mounting bolts. Tighten the lower mounting bolt to 46 ft. lbs. (63 Nm) and the upper transaxle-to-starter mounting bolt to 71 ft. lbs. (96 Nm).
  8.  
  9. Install the oil filter.
  10.  
  11. Install the air cleaner assembly.
  12.  
  13. Install the alternator bracket.
  14.  
  15. Install the dipstick, bolt and oil fill tube.
  16.  
  17. Install the alternator.
  18.  
  19. Fasten the A/C rail line clip.
  20.  
  21. Install the coolant reservoir.
  22.  
  23. Install the serpentine belt.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Refill the engine oil as necessary and check for leaks.
  28.  

1992-94 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air induction tubing, as necessary.
  4.  
  5. Position a suitable drain pan under the oil filter, then remove the oil filter.
  6.  
  7. Remove the starter mounting bolts.
  8.  
  9. Position the starter to access the wiring, then disconnect the electrical wiring.
  10.  
  11. Remove the starter from the vehicle.
  12.  

To install:
  1. Position the starter to the engine and connect the electrical wiring.
  2.  
  3. Install the upper and lower mounting bolts and tighten to 74 ft lbs. (100 Nm).
  4.  
  5. Install the oil filter.
  6.  
  7. Reconnect the air induction tubing, if removed.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Refill with engine oil and check for leaks.
  12.  

2.8L and 3.1L Engines

See Figures 3, 4, 5 and 6

1988-89 VEHICLES
  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Raise and support the car safely.
  4.  
  5. Remove the solenoid wires and the battery cable from the starter.
  6.  
  7. For8989 vehicles, place a drain pan under the engine oil pan and remove the oil filter.
  8.  
  9. Remove the 2 starter motor to engine bolts and remove the starter. Note the location and number of any shims (if used).
  10.  
  11. Installation is the reverse of removal. Tighten the 2 retaining bolts to 32 ft. lbs. (43 Nm).
  12.  

1990 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly, as required.
  4.  
  5. Raise and safely support the vehicle.
  6.  

If equipped with an oil cooler, remove the oil filter and position the hose next to the starter to the side.

  1. Remove the air conditioning compressor brace attaching nuts and remove the brace from the engine, as required.
  2.  
  3. Remove flywheel inspection cover bolts and remove the inspection cover, as required.
  4.  
  5. Remove the starter attaching bolts.
  6.  
  7. Carefully lower the starter and remove the shims. Note the number and position of any shims.
  8.  
  9. Detach the electrical wiring connections at the starter.
  10.  

To install:
  1. Attach the electrical connections to the starter.
  2.  
  3. Position the shims in place and install the starter and mounting bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  4.  

If equipped with an oil cooler, position the cooler hose next to the starter motor and install the oil filter.

  1. If removed, install the flywheel inspection cover and attaching bolts.
  2.  
  3. If removed, install the air conditioning compressor brace and attaching nuts.
  4.  
  5. Lower vehicle and connect the negative battery cable.
  6.  
  7. If removed, install the air cleaner assembly.
  8.  
  9. Crank the engine and check the starter operation.
  10.  

1991-96 VEHICLES
  1. Disconnect the negative battery cable at the battery.
  2.  
  3. Raise and support the car safely.
  4.  
  5. Remove the starter motor-to-engine bolt(s).
  6.  
  7. If necessary, remove the retaining bolts, then remove the flywheel dust cover.
  8.  
  9. Remove the remaining starter-to-engine bolt(s).
  10.  
  11. Partially lower the starter to access the wiring.
  12.  
  13. Support the starter, then disconnect the electrical leads.
  14.  
  15. Remove the starter from the vehicle. Note the location and number of any shims (if used).
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Remove the accessible starter mounting bolts



Click image to see an enlarged view

Fig. Fig. 4: On some vehicles it may be necessary to unfasten the flywheel dust cover retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 5: ... then remove the flywheel dust cover from the starter



Click image to see an enlarged view

Fig. Fig. 6: While supporting the starter, remove the remaining mounting bolt

To install:
  1. Support the starter motor and attach the electrical leads.
  2.  
  3. Raise the starter into installed position and install the starter-to-engine bolt(s). Tighten to 32 ft. lbs. (43 Nm).
  4.  
  5. If removed, install the flywheel dust cover and secure with the retaining bolts.
  6.  
  7. Tighten the remaining starter mounting bolt(s) to 32 ft. lbs. (43 Nm).
  8.  
  9. Carefully lower the vehicle, then connect the negative battery cable.
  10.  

 
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