Malibu, Malibu MAXX 2006-2008

Starter

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter motor electrical connections
     
    Starter motor mounting bolts
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor
     
    Starter motor mounting bolts. Tighten the mounting bolts for 2005-06 models to 30 ft. lbs. (40 Nm).
     
    Tighten the mounting bolts for 2007-08 models to 39 ft. lbs. (53 Nm).
     
    Starter motor electrical connections. Tighten the battery cable for 2005-06 models to 7 ft. lbs. (10 Nm). Tighten the solenoid cable to 4 ft. lbs. (5 Nm).
     
    Tighten the battery cable for 2007-08 models to 89 inch. lbs. (10 Nm). Tighten the solenoid cable to 27 inch. lbs. (3 Nm).
     
    Negative battery cable
     

  2.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Flywheel inspection cover
     
    Starter motor electrical connections
     
    Starter motor mounting bolts
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor and mounting bolts. Tighten mounting bolts for 2005-06 models to 30 ft. lbs. (40 Nm).
     
    Tighten mounting bolts for 2007-08 models to 32 ft. lbs. (43 Nm).
     
    Starter motor electrical connections. Tighten battery cable to 89 inch. lbs. (10 Nm). Tighten the solenoid cable to 27 inch lbs. (3 Nm).
     
    Flywheel inspection cover. Tighten mounting bolts to 89 inch. lbs. (10 Nm).
     
    Negative battery cable
     

  2.  

3.9L 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 torque converter cover bolt.
  8.  
  9. Remove the torque converter cover.
  10.  
  11. Disconnect the engine wiring harness electrical connector from the starter motor.
  12.  
  13. Remove the positive battery cable nut from the starter solenoid.
  14.  
  15. Remove the positive battery cable and the engine wiring harness terminal from the starter solenoid.
  16.  
  17. Remove the starter motor bolts.
  18.  
  19. Remove the starter motor.

    Click image to see an enlarged view

    Fig. 3.9L Starter motor and mounting bolts

  20.  

To install:

  1. Install the starter motor.
  2.  
  3. Install the starter motor bolts and tighten to 32 inch. lbs. (42 Nm).
  4.  
  5. Install the engine wiring harness terminal and the positive battery cable to the starter solenoid.
  6.  
  7. Tighten the solenoid cable to 27 inch lbs. (3 Nm).
  8.  
  9. Install the positive battery cable nut to the starter solenoid. Tighten battery cable to 89 inch. lbs. (10 Nm).
  10.  
  11. Connect the engine wiring harness electrical connector to the starter motor.
  12.  
  13. Install the torque converter cover.
  14.  
  15. Install the torque converter cover bolt and tighten to 89 inch. lbs. (10 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  

Testing & Troubleshooting



Voltage Drop Test

NOTE
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 volts 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 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    NOTE
    Many automotive parts 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.

  14.  

 
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