GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

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.

    2.2L engine: No load test @ 10 volts--45-75 amps, RPM at drive pinion--6,000-11,000 rpm
     
    2.3L engine: No load test @ 10 volts--52-76 amps, RPM at drive pinion--6,000-12,000 rpm
     
    2.5L engine: No load test @ 10 volts--50-75 amps, RPM at drive pinion--6,000-11,900 rpm
     
    2.8L engine: No load test @ 10 volts--50-75 amps, RPM at drive pinion--6,000-11,900 rpm
     
    3.1L engine: No load test @ 10 volts--45-75 amps, RPM at drive pinion--6,000-11,000 rpm
     
    1991-92 3.4L engine: No load test @ 10 volts--50-75 amps, RPM at drive pinion--7,000-11,000 rpm
     
    1992-95 3.4L engine: No load test @ 10 volts--45-70 amps, RPM at drive pinion--6,500-11,000 rpm
     
    1996 3.4L engine: No load test @ 10 volts--64-95 amps, RPM at drive pinion--2,825-3,275 rpm
     
    3.8L engine: No load test @ 10 volts--45-75 amps, RPM at drive pinion--8,600-13,000 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



2.2L Engine

See Figure 2

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Unfasten the bolts from the flywheel inspection cover, then remove the cover.
  6.  
  7. Detach the starter electrical connector.
  8.  
  9. Remove the stud from the bracket.
  10.  
  11. Unfasten the starter motor retaining bolts, then remove the starter motor from the engine.
  12.  
  13. Remove the bracket from the starter.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: Starter motor mounting-2.2L engine

To install:
  1. Install the bracket on the starter and tighten the retaining nuts to 80 inch lbs. (9 Nm).
  2.  


WARNING
Before installing the starter in the vehicle, make sure the electrical terminals are secure by tightening the nut next to the cap on the solenoid battery terminal. If this terminal is not tight, starter damage may occur.

  1. Secure the electrical terminal on the solenoid. Tighten the solenoid battery terminal inside nut to 84 inch lbs. (9.5 Nm).
  2.  
  3. Attach the electrical connections to the starter. Tighten the solenoid battery outside nut to 84 inch lbs. (9.5 Nm) and the solenoid "S'' terminal outside nut to 22 inch lbs. (2.5 Nm).
  4.  
  5. Position the starter in the engine and install the retaining bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the bracket to the engine. Tighten the retaining bolt to 26 ft. lbs. (32 Nm).
  8.  
  9. Install the flywheel inspection cover and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  10.  
  11. Carefully lower the vehicle, then connect the negative battery cable.
  12.  

2.3L Engine

See Figure 3

  1. Loosen the air inlet hose clamp at the throttle body.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Detach and plug the coolant reservoir hose at the radiator filler neck.
  8.  
  9. Remove the coolant recovery reservoir.
  10.  
  11. Unfasten the intake manifold brace bolts.
  12.  
  13. Place a suitable drainPan under the oil filter, then remove the filter.
  14.  
  15. Unfasten the starter retaining bolts, lower the starter onto the frame member, detach the starter electrical connectors, then remove the starter from the vehicle.
  16.  



Click image to see an enlarged view

Fig. Fig. 3: Starter removal and installation-2.3L engine

To install:
  1. Position the starter into the vehicle, attach the electrical connectors, then tighten the retaining bolts to 32 ft. lbs. (43 Nm).
  2.  
  3. Install a new oil filter and add engine oil, as needed.
  4.  
  5. Install the intake manifold brace, coolant reservoir and hoses.
  6.  
  7. Add coolant, if needed.
  8.  
  9. Install the air cleaner assembly and connect the air inlet hose at the throttle body.
  10.  
  11. Connect the negative battery cable, then check the oil level and add if necessary.
  12.  

2.5L Engine

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Unfasten the flywheel inspection cover bolts, then remove the cover.
  6.  
  7. Remove the stud from the starter support bracket.
  8.  
  9. Unfasten the starter mounting bolts and shim(s), if used.
  10.  
  11. Remove the starter motor. Be careful not to damage the starter wires by letting the starter hang.
  12.  
  13. While holding the starter motor, detach the electrical connectors from the starter solenoid.
  14.  
  15. Remove the bracket from the starter.
  16.  



Click image to see an enlarged view

Fig. Fig. 4: Starter motor mounting-2.5L engine

To install:
  1. Install the bracket to the starter.
  2.  
  3. Attach the starter electrical connectors.
  4.  
  5. Install the starter adjustment shims, if used.
  6.  
  7. Position the starter to the engine mounting flange, then tighten the retaining bolts to 32 ft. lbs. (43 Nm).
  8.  
  9. Install the bracket to the engine, then tighten the stud to 18 ft. lbs. (25 Nm).
  10.  
  11. Install the inspection cover and secure with the retaining bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  12.  
  13. Carefully lower the vehicle, then connect the negative battery cable.
  14.  

2.8L and 3.1L Engines
1988-94 VEHICLES

See Figures 5, 6, 7 and 8

  1. Remove the air cleaner and duct assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. If equipped with an engine oil cooler, drain the engine oil, remove the oil filter and position the hose next to the starter motor to the side.
  8.  
  9. Remove the nut from the brace at the air conditioning compressor, nut from the brace at the engine and the brace.
  10.  
  11. Unfasten the retaining bolts, then remove the flywheel inspection cover.
  12.  



Click image to see an enlarged view

Fig. Fig. 5: Unfasten the retaining bolts ...



Click image to see an enlarged view

Fig. Fig. 6: ... then remove the flywheel cover

  1. Remove the starter bolts and shims, if equipped. Do not let the starter hang from the starter wires.
  2.  



Click image to see an enlarged view

Fig. Fig. 7: An extension may be needed to access the starter mounting bolts



Click image to see an enlarged view

Fig. Fig. 8: Remove the starter motor and any shims that may have been used

  1. Detach the starter wires from the solenoid, then remove the starter from the vehicle.
  2.  

To install:
  1. While supporting the starter, connect the starter wires at the solenoid.
  2.  
  3. Install the starter motor-to-engine mount with the shims, if equipped, and the mounting bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  4.  
  5. If equipped with an engine oil cooler, reposition the hose next to the starter motor, install the oil filter and refill the engine with the proper amount of engine oil.
  6.  
  7. Install the flywheel inspection cover and tighten the bolts.
  8.  
  9. Install the starter support brace to the air conditioning compressor and tighten the nut to 23 ft. lbs. (31 Nm).
  10.  
  11. Carefully lower the vehicle, then connect the negative battery cable.
  12.  
  13. Install the air cleaner and duct assembly.
  14.  

1995-96 VEHICLES

See Figure 9

  1. Remove the air cleaner and duct assembly.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the oil filter splash shield.
  8.  
  9. Detach the starter electrical connector(s).
  10.  
  11. Unfasten the starter mounting bolts, remove any shims, then remove the starter from the vehicle.
  12.  



Click image to see an enlarged view

Fig. Fig. 9: Starter motor mounting-1996 3.1L engine shown

To install:
  1. Position the starter to the engine. Install the mounting bolts and shims (if equipped). Tighten the bolts to 32 ft. lbs. (43 Nm).
  2.  
  3. Attach the electrical connector(s) to the starter. Tighten the starter solenoid switch BAT terminal outer nut to 84 inch lbs. (9.5 Nm) and the starter solenoid switch "S'' terminal nut to 22 inch lbs. (2.5 Nm).
  4.  
  5. Install the oil filter splash shield.
  6.  
  7. Carefully lower the vehicle, then connect the negative battery cable.
  8.  
  9. Install the air cleaner and duct assembly.
  10.  

3.4L Engine

See Figures 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine oil cooler assembly. For details, please refer to the procedure located in Engine & Engine Overhaul of this repair guide.
  4.  
  5. If equipped with an automatic transaxle, unfasten the flywheel inspection cover bolts, then remove the cover.
  6.  
  7. Detach the electrical connections from the starter.
  8.  



Click image to see an enlarged view

Fig. Fig. 10: Detach the starter electrical connections ...



Click image to see an enlarged view

Fig. Fig. 11: ... then unfasten the retaining bolts and remove the starter from the vehicle

  1. Unfasten the starter motor retaining bolts, then remove the starter.
  2.  

To install:

WARNING
Before installing the starter to the engine, make sure the electrical terminals are secure by tightening the nut next to the cap on the solenoid battery terminal. If this terminal is not tight, starter damage may occur.

  1. Secure the electrical terminal on the solenoid. Tighten the solenoid battery terminal inside nut to 84 inch lbs. (9.5 Nm). -27 inch lbs. (22-27 Nm).
  2.  
  3. Position the starter motor, then install the retaining bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  4.  
  5. If equipped, install the flywheel inspection cover and tighten the retaining bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the engine oil cooler assembly, as outlined in Engine & Engine Overhaul of this repair guide.
  8.  
  9. Connect the negative battery cable.
  10.  

3.8L Engine
1991-92 VEHICLES

See Figure 12

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the right side cooling fan.
  4.  
  5. Remove the serpentine drive belt, as outlined in Routine Maintenance of this repair guide.
  6.  
  7. Disconnect the A/C compressor upper support brace, then lay the compressor in the fan opening.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Detach the engine oil cooler lines at the flex connector.
  12.  
  13. Unfasten the retaining bolts, then remove the flywheel inspection cover.
  14.  
  15. Remove the starter motor retaining bolts, carefully lower the starter and remove the shims, if used.
  16.  
  17. Detach the starter motor wiring, then remove the starter from the vehicle.
  18.  



Click image to see an enlarged view

Fig. Fig. 12: Starter motor removal and installation-1992 3.8L engine shown

To install:
  1. Attach the electrical connectors to the starter terminals. Tighten the battery terminal nut to 80 inch lbs. (9 Nm) for 1991 vehicles and to 12 ft. lbs. (16 Nm) for 1992 vehicles. Tighten the "S'' terminal nut to 27-35 inch lbs. (3-4 Nm).
  2.  
  3. Position the starter motor and shims, if used, to the engine and tighten the mounting bolts to 32 ft. lbs. (43 Nm).
  4.  
  5. Install the flywheel inspection cover. Tighten the retaining bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Attach the engine oil cooler lines at the flex connector.
  8.  
  9. Carefully lower the vehicle and position the A/C compressor.
  10.  
  11. Install the A/C compressor upper support brace.
  12.  
  13. Install the serpentine drive belt, as outlined in Routine Maintenance of this repair guide.
  14.  
  15. Install the right side cooling fan
  16.  
  17. Connect the negative battery cable.
  18.  

1993 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the left side cooling fan.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Detach the engine oil level sensor and knock sensor electrical connectors.
  8.  
  9. Disconnect the engine oil cooler pipe from the pipe clip.
  10.  
  11. Unfasten the retaining bolts, then remove the flywheel inspection cover.
  12.  
  13. Remove the starter mounting bolts, then detach the electrical connections from the starter.
  14.  
  15. Carefully lower the vehicle, then remove the starter motor from the engine.
  16.  

To install:
  1. Position the starter motor to the engine, then raise and safely support the vehicle.
  2.  


WARNING
Before bolting the starter to the engine, make sure the electrical terminals are secure by tightening the nut next to the cap on the solenoid battery terminal. If this terminal is not tight, the cap may be damaged during installation and starter failure may result.

  1. Secure the electrical terminals on the solenoid. Tighten the battery terminal inside nut to 12 ft. lbs. (16 Nm) and the "S'' terminal inside nut to 22 inch lbs. (2.5 Nm).
  2.  
  3. Attach the starter electrical connections. Tighten the battery terminal outside nut to 12 ft. lbs. and the "S'' terminal nut to 22 inch lbs. (2.5 Nm).
  4.  
  5. Install the starter mounting bolts and tighten to 32 ft. lbs. (43 Nm).
  6.  
  7. Install the flywheel inspection cover and secure with the retaining bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  8.  
  9. Connect the engine oil cooler pipe to the pipe clip.
  10.  
  11. Attach the engine oil level sensor and knock sensor electrical connectors.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Install the left side cooling fan.
  16.  
  17. Connect the negative battery cable, then check the engine oil level and add if necessary.
  18.  

1994 VEHICLES
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the coolant recovery reservoir.
  4.  
  5. Remove the ECM cover.
  6.  
  7. Remove the serpentine belt, as outlined in Routine Maintenance of this repair guide.
  8.  
  9. Remove the right side cooling fan.
  10.  
  11. Unfasten the A/C compressor heat shield and screw. Detach the compressor electrical connectors. Remove the A/C compressor bracket brace, nut and bolt.
  12.  
  13. Remove the A/C compressor bolts and move the compressor aside.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Disconnect the engine wiring harness clamps at the lower front of the frame.
  18.  
  19. Unfasten the flywheel inspection cover screws, then remove the cover.
  20.  
  21. Detach the oil level sensor electrical connector.
  22.  
  23. Unfasten the starter motor bolts, pull the starter down, detach the electrical connections, then remove the starter from the vehicle.
  24.  

To install:

WARNING
Before bolting the starter to the engine, make sure the electrical terminals are secure by tightening the nut next to the cap on the solenoid battery terminal. If this terminal is not tight, the cap may be damaged during installation and starter failure may result.

  1. Secure the electrical terminals on the solenoid. Tighten the battery terminal inside nut to 12 ft. lbs. (16 Nm) and the "S'' terminal inside nut to 22 inch lbs. (2.5 Nm).
  2.  
  3. Attach the starter electrical connections. Tighten the battery terminal outside nut to 12 ft. lbs. and the "S'' terminal nut to 22 inch lbs. (2.5 Nm).
  4.  
  5. Install the starter motor, then secure using the retaining bolts. Tighten the bolts to 32 ft. lbs. (43 Nm).
  6.  
  7. Attach the oil level sensor electrical connector.
  8.  
  9. Install the flywheel cover and secure with the retaining screws. Tighten the screws to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the engine wiring harness clamps to the lower front of the frame.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Install the A/C compressor and secure with the retaining bolts. Tighten the front bolts to 39 ft. lbs. (53 Nm) and the rear bolts to 23 ft. lbs. (31 Nm).
  16.  
  17. Install the A/C compressor bracket brace, bolt and nut. Tighten the bolt to 19 ft. lbs. (26 Nm) and the nut to 24 ft. lbs. (33 Nm). Attach the A/C compressor electrical connectors, then install the compressor heat shield and screw.
  18.  
  19. Install the right side engine cooling fan.
  20.  
  21. Install the serpentine drive belt.
  22.  
  23. Fasten the ECM cover.
  24.  
  25. Install the coolant recovery reservoir.
  26.  
  27. Connect the negative battery cable, then check the engine oil level and adjust as necessary.
  28.  

1995-96 VEHICLES

See Figure 13

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper mounting bracket above the radiator.
  4.  
  5. Detach the electrical connections at the coolant fan, then remove the fan.
  6.  
  7. Disconnect the upper and lower oil cooler pipes from the radiator.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Unfasten the retainers from the engine harness and position them away from the starter.
  12.  
  13. Disconnect both lower oil cooler hoses from the radiator.
  14.  
  15. Detach the starter electrical connections.
  16.  
  17. Remove the upper flywheel inspection cover.
  18.  
  19. Unfasten the mounting bolts/screws, then remove the starter and shims (if used) from the engine.
  20.  



Click image to see an enlarged view

Fig. Fig. 13: Starter motor mounting-1996 3.8L engine shown

To install:
  1. Position the starter and shims (if used) to the engine, then secure with the mounting bolts/screws. Tighten to 32 ft. lbs. (43 Nm).
  2.  
  3. Attach the electrical connections to the starter. Tighten the solenoid battery terminal outside nut to 12 ft. lbs. (16 Nm). and the solenoid "S'' terminal inside nut to 22 inch lbs. (2.5 Nm).
  4.  
  5. Position the upper inspection cover, then secure with the retainers to 89 inch lbs. (10 Nm).
  6.  
  7. Attach both lower oil cooler hoses to the radiator.
  8.  
  9. Fasten the engine wire harness and retainers.
  10.  
  11. Carefully lower the vehicle.
  12.  
  13. Attach the oil cooler pipes to the radiator.
  14.  
  15. Install the coolant fan and attach the electrical connectors.
  16.  
  17. Install the upper engine mounting bracket and tighten the bolt/screws to 32 ft. lbs. (43 Nm).
  18.  
  19. Connect the negative battery cable, then check the engine oil level and add as necessary.
  20.  

 
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