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    2007 Mercedes Benz CL600 5.5L SFI Turbo 12cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    GM Prizm/Nova 1985-1993 Repair Guide

    Starter

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    TESTING



    See Figure 1

    1. Inspect the battery specific gravity and electrolyte level. Check the specific gravity of each cell. The standard specific gravity of each cell is 1.25-1.27 when fully charged at 68°F. On a Delco battery with a maintenance eye look for a GREEN DOT which means the battery is fully charged. The DARK eye (GREEN DOT NOT VISIBLE) means the battery must be charged. The CLEAR or LIGHT YELLOW eye means replace the battery.
    2.  
    3. Check the battery terminals are not loose or corroded. Check the fusible link for continuity.
    4.  
    5. For further starting system troubleshooting, refer to the troubleshooting chart to find the problem and possible cause and remedy. Replace or repair the necessary items.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 1: Starter troubleshooting chart

    REMOVAL & INSTALLATION



    1985-90

    See Figure 2

    1. Disconnect the negative battery cable.
    2.  
    3. Disconnect all the wiring from the starter terminals.
    4.  
    5. On Nova, remove the transaxle cable and bracket from the transaxle.
    6.  
    7. Remove the starter mounting bolts.
    8.  
    9. Remove the starter.
    10.  
    11. Reassemble in reverse order of disassembly.
    12.  



    Click image to see an enlarged view

    Fig. Fig. 2: Starter installation - 1985-92

    1991-92 Prizm

    See Figure 2

    BASE AND LSi MODELS
    1. Disconnect the negative battery cable.
    2.  
    3. Disconnect the positive battery cable from the starter solenoid by removing the nut from terminal 30 stud.
    4.  
    5. Disconnect the ignition switch lead from terminal 50.
    6.  
    7. Remove the 2 starter assembly retaining bolts and remove the starter assembly.
    8.  
    9. To install, reverse the removal procedures. Torque the starter-to-engine bolts to 26 ft. lbs. (35 Nm).
    10.  

    GSi MODEL
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the rear cooling fan assembly.
    4.  
    5. Raise and safely support the vehicle safely.
    6.  
    7. Remove the right and left splash shields.
    8.  
    9. Disconnect the oxygen sensor connector from the front exhaust pipe.
    10.  
    11. Disconnect the front exhaust pipe.
    12.  
    13. Remove the starter assembly mounting bolts.
    14.  
    15. Disconnect the positive battery cable from the starter solenoid by removing the nut from terminal 30 stud.
    16.  
    17. Disconnect the ignition switch lead from terminal 50. Remove the starter assembly from the vehicle.
    18.  
    19. To install, reverse the removal procedures. Torque the starter-to-engine bolts to 29 ft. lbs. (39 Nm).
    20.  

    1993
    To install:

    See Figure 3

    1. Disconnect the negative battery cable.
    2.  
    3. Disconnect the intake air temperature (IAT) sensor from the air cleaner (ACL). Loosen the (ACL) hose clamp bolt.
    4.  
    5. Remove the 4 ACL cap clips, hose ACL cap from the lower housing and throttle body.
    6.  
    7. Disconnect the wire clamp from the starter motor.
    8.  
    9. Disconnect the starter motor electrical connector.
    10.  
    11. Remove the 1 nut and the positive battery cable from the starter motor terminal.
    12.  
    13. Remove the 2 bolts and the starter motor from the vehicle.
    14.  
    15. Install the starter motor and tighten the 2 retaining bolts to 29 ft. lbs. (39 Nm).
    16.  
    17. Install the 1 nut and the positive battery cable to the starter motor terminal.
    18.  
    19. Connect the starter motor electrical connector.
    20.  
    21. Connect the wire clamp to the starter motor.
    22.  
    23. Connect the hose ACL cap to the lower housing and throttle body and secure with the 4 ACL cap clips.
    24.  
    25. Connect the intake air temperature (IAT) sensor to the air cleaner (ACL). Tighten the (ACL) hose clamp bolt.
    26.  
    27. Connect the negative battery cable.
    28.  



    Click image to see an enlarged view

    Fig. Fig. 3: Starter installation - 1993

    SOLENOID REPLACEMENT



    See Figure 4

    The starter solenoid or magnetic switch is an integral part of the starter. It cannot be replaced without complete disassembly of the starter.

    1. Remove the starter from the car.
    2.  
    3. Disconnect the wire lead from the magnetic switch terminal.
    4.  
    5. Remove the 2 long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
    6.  
    7. On 1.0kw (1000 watt) starters, remove the felt seal. On 1.4kw starters, remove the O-ring.
    8.  
    9. To remove the starter housing from the magnetic switch assembly:
      1. For 1.0 kw starters, remove the 2 screws and remove the starter housing with the idler gear and clutch assembly.
      2.  
      3. For 1.4kw units, remove the 2 screws and remove the starter housing with the pinion gear, idler and clutch assembly.
      4.  

    10.  
    11. Using a magnetic tool, remove the spring and steel ball from the clutch shaft hole.
    12.  
    13. Remove the end cover from the field frame.
    14.  
    15. On 1.4kw units, remove the O-ring.
    16.  
    17. Use a small screwdriver or steel wire to separate the brush springs and remove the brushes from the holder.
    18.  
    19. Pull the brush holder off the field frame.
    20.  
    21. Remove the armature from the field frame.
    22.  
    23. Perform testing and repairs as necessary:
      1. Measure the length of the brushes. If they are less than the acceptable minimum length, replace them with new brushes.
      2.  

    24.  

    Standard Length:


    1.0kw - 13mm
     
    1.4kw - 15mm
     

    Minimum Length:


    1.0kw - 8.5mm
     
    1.4kw - 10mm
     

    1. Check the magnetic switch by performing the pull-in coil open circuit test. Using an ohmmeter, check for continuity between terminal 50 and terminal C. If there is no continuity, replace the magnetic switch.
    2.  
    3. Check the hold in coil of the magnetic switch. Use the ohmmeter to check for continuity between terminal 50 and the body (case) of the unit. If there is no continuity, replace the switch.
    4.  
    5. To reassemble the starter, apply high-temperature grease to the armature bearings and insert the armature into the field frame.
    6.  
    7. Use a screwdriver or a steel wire to hold the brush spring back and install the brushes into the holder(s).
    8.  


    WARNING
    Make certain the positive wires to the brushes are not grounded or touching surrounding parts.

    1. For 1.4kw starters, install the O-ring on the field frame.
    2.  
    3. Install the end cover on the field frame.
    4.  
    5. Apply grease to the ball and spring and insert them into the clutch shaft hole.
    6.  
    7. Install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
      1. For 1.0kw starters, place the clutch assembly, idler gear and bearing in the starter housing.
      2.  
      3. For 1.4kw starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.
      4.  

    8.  
    9. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the 2 screws.
    10.  
    11. On 1.0kw units, install the felt seal on the armature shaft. On 1.4kw units, install the O-ring on the field frame.
    12.  
    13. Install the field frame with armature onto the magnetic switch assembly and install the 2 through bolts.
    14.  

    There is a protrusion or tab on each part; make sure you line them up correctly.

    1. Connect the wire to the terminal on the magnetic switch.
    2.  
    3. Reinstall the starter on the vehicle.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 4: Exploded view of starter motors

     
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