For 1990-2009 cars

### Solenoid Removal Procedure

1. Remove the starter from the vehicle. Refer to Starter Motor Replacement .
2. Scribe matchmarks (2) on the solenoid and the drive housing to ensure proper solenoid installation.
3. Remove the retaining nut and the field coil lead wire (2) from the solenoid.
4. Remove the 2 screws and the solenoid (1) from the drive housing.

### Manual Transaxle Equipped Vehicles

#### Starter Disassembly Procedure

1. Remove the following components from the yoke:

• | Two bolts

• | Two screws

• | The commutator end cover

2. Remove the commutator end bushing and the washers from the yoke.
3. Scribe matchmarks on the yoke and the drive housing to ensure proper assembly.
4. Remove the drive housing from the yoke (3).
5. Remove the pinion drive lever from the drive housing (1).
6. Remove the armature from the yoke.
7. Remove the brush holder (3) from the yoke (2).
8. Remove the brushes (4) from the brush holder.
9. Remove the drive bushing from the armature.
10. Pull the armature stop ring (3) toward the overrunning clutch assembly (2) and remove the armature retaining ring (4) from the armature (1).
11. Remove the armature stop ring and the overrunning clutch assembly from the armature.

### Automatic Transaxle Equipped Vehicles

#### Starter Disassembly Procedure

1. Remove the following components:

• | Two screws

• | Two bolts

• | The commutator end cover with the spring washer (2)

2. Remove the brush holder from the yoke.
3. Remove the brushes from the brush holder.
4. Remove the armature bushing from the armature.
5. Remove the armature (1) from the yoke (2).
6. Scribe matchmarks on the yoke and drive housing to ensure proper assembly.
7. Remove the yoke from the drive housing.
8. Remove the armature bearing from the gear shaft.
9. Remove the idle gear retainer (2) and three idle gears (3) from the drive housing (1).
10. Remove the pinion drive lever seal (3) and the plate (4) from the drive housing (1).
11. Remove the gear shaft assembly with the pinion drive lever (4) from the drive housing (1).
12. Pull the overrunning clutch stop ring (4) towards the overrunning clutch assembly (1) and remove the overrunning clutch retaining ring (2).
13. Remove the overrunning clutch stop ring and overrunning clutch assembly from the gear shaft assembly.
14. Remove the internal gear from the gear shaft (3).

### Starter Cleaning, Inspection and Testing

#### Tools Required

• | J 544-01 Tension Scale

• | J 8001 Dial Indicator

• | J 26900-13 Magnetic Base

• | J 26900-5 Vernier Caliper

• | J 39200 Digital Multimeter

Notice: Do not use grease dissolving solvents for cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and damage the armature and the field coil insulation.

1. Clean all starter motor parts.
2. Remove dirt and burn marks from the commutator end (2) of the armature (1) by sanding with a #300 or #400 grit sandpaper. Wipe the parts with a clean shop cloth.
3. Place the armature onto a pair of V-blocks (1). Measure the commutator run-out using the J 8001 with the J 26900-13 . Replace the armature if the run-out exceeds the maximum.

Standard Commutator Run-out
0.05 mm (0.002 in)

Maximum Commutator Run-out
0.40 mm (0.016 in)

4. Measure the outside diameter of the commutator (2) using the J 26900-5 . Replace the armature if the diameter of the commutator is less than the minimum.

Automatic transaxle -- Standard Commutator Outside Diameter
29.4 mm (1.157 in

Automatic transaxle -- Minimum Commutator Outside Diameter
28.8 mm (1.134 in)

Manual transaxle -- Standard Commutator Outside Diameter
32.0 mm (1.260 in)

Manual transaxle -- Minimum Commutator Outside Diameter
31.4 mm (1.236 in)

5. Measure the commutator insulation depth (2).

Automatic Transaxle -- Standard Insulation Depth
0.5-0.8 mm (0.020-0.031 in)

Manual Transaxle -- Standard Insulation Depth
0.4-0.6 mm (0.016-0.024 in)

6. If the insulation depth is less than 0.2 mm (0.008 in), replace the armature.
7. Measure the resistance between the armature core (1) and the commutator (2) using J 39200 . If the resistance is 5.0 ohms or less, the armature is grounded . Replace the armature.
8. Measure the resistance between the commutator segments using J 39200 . If resistance is greater than 5.0 ohms at any test point, an open circuit exists in the commutator. Replace the armature.
9. With a manual transaxle, measure the resistance between the field coil lead wire and the yoke using J 39200 . If the resistance is 5 ohms or less, the field windings are grounded. Replace the yoke.
10. Measure the brush (1) length using J 26900-5 . If the brush length is less than the minimum, replace the brush.

Automatic Transaxle -- Standard Brush Length
17.5 mm (0.69 in)

Automatic Transaxle -- Minimum Brush Length
12.0 mm (0.47 in)

Manual Transaxle -- Standard Brush Length
17.0 mm (0.67 in)

Manual Transaxle -- Minimum Brush Length
11.5 mm (0.45 in)

11. Measure the resistance between the positive brush holder and the negative brush holder using J 39200 . If the resistance is 5.0 ohms or less, the brush holder is grounded. Replace the brush holder.
12. Measure the brush spring (2) tension using J 544-01 . If the tension is less than the minimum, replace the spring.

Automatic Transaxle -- Standard Tension
2.1 kg (4.63 lbs)

Automatic Transaxle -- Minimum Tension
0.7 kg (1.54 lbs)

Manual Transaxle -- Standard Tension
1.6 kg (3.53 lbs)

Manual Transaxle -- Minimum Tension
1.0 kg (2.20 lbs)

13. Measure the starter solenoid (1) pull-in coil resistance between terminal S (2) and terminal M using J 39200 . If the resistance is greater than 5.0 ohms, the pull-in coil is open. Replace the starter solenoid.
14. Measure the starter solenoid (1) hold-in coil resistance between terminal S (3) and the solenoid case (1) usingJ 39200 . If the resistance is greater than 5.0 ohms, the hold-in coil is open. Replace the starter solenoid.
15. Inspect the pinion drive lever (4) for wear. Replace as necessary.
16. Inspect the overrunning clutch (1) for wear, damage or other abnormal conditions. Verify that the clutch locks when turned in the drive direction, and rotates smoothly in the reverse direction. Replace as necessary.
17. Inspect the overrunning clutch spline teeth (1) for wear or damage. Replace as necessary.
18. Inspect the armature bushing for wear and damage. Replace as necessary.
19. With automatic transaxles, inspect the armature bearing (1) for wear and damage. Replace as necessary.
20. With manual transaxles, inspect the commutator end bushing for wear and damage. Replace as necessary.
21. Inspect the starter solenoid plunger operation by first pressing in the plunger and then releasing the plunger. If the plunger does not return to its original position quickly, replace the starter solenoid (1).
22. Inspect the internal gear assembly (1) and idle gears (2,3) for wear, damage or other abnormal conditions. Replace as necessary.
23. Inspect the brush springs for corrosion or damage. Also inspect the brush holder and the insulation on the positive plates for wear. Replace the components as needed.

### Manual Transaxle Equipped Vehicles

#### Starter Assembly Procedure

1. Lightly grease the armature shaft and the overrunning clutch with Lubriplate lubricant GM P/N 1050109, or the equivalent.
2. Install the overrunning clutch assembly (2) to the armature (1).
3. Install the armature retaining ring (4) to the armature. Slide the armature stop ring (3) away from the overrunning clutch assembly to cover the armature retaining ring.
4. Lightly grease the drive bushing with Lubriplate lubricant GM P/N 1050109, or the equivalent.
5. Install the drive bushing to the armature.
6. Install the brush holder (3) to the yoke (2).
7. Install the brushes (4) to the brush holder (1).

Important: The brushes must contact the commutator end after installation.

8. Install the armature to the yoke (2).
9. Lightly grease the pinion drive lever contact points with Lubriplate lubricant GM P/N 1050109, or the equivalent.
10. Install the pinion drive lever to the drive housing.
11. Install the drive housing (1) to the yoke (3), aligning the drive housing-to-yoke matchmarks.
12. Lightly grease the commutator end bushing with Lubriplate lubricant GM P/N 1050109, or the equivalent.
13. Install the commutator end bushing and washers to the yoke.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

14. Install the commutator end cover to the yoke. Secure with 2 bolts and 2 screws.

Tighten
Tighten the commutator end cover bolts to 8 N·m (71 in lb).

15. Install the solenoid.

### Automatic Transaxle Equipped Vehicles

#### Starter Assembly Procedure

1. Lightly grease the gear shaft with Lubriplate lubricant GM P/N 1050109, or the equivalent.
2. Install the internal gear to the gear shaft (3).
3. Install the overrunning clutch assembly and the overrunning clutch stop ring to the gear shaft assembly.
4. Install the overrunning clutch retaining ring to the gear shaft assembly. Slide the overrunning clutch stop ring (4) away from the overrunning clutch assembly to cover the overrunning clutch retaining ring (2).
5. Lightly grease the pinion drive lever contact points with Lubriplate lubricant GM P/N 1050109, or the equivalent.
6. Install the gear shaft assembly with the pinion drive lever (4) to the drive housing (1).
7. Install the pinion drive lever seal (3) and the plate (4) to the drive housing (1).
8. Lightly grease the idle gears with Lubriplate lubricant GM P/N 1050109, or the equivalent.

Important: Align the notches in the idle gear retainer with the bolt holes in the drive housing.

9. Install the 3 idle gears (3) to the drive housing (1). Secure with the idle gear retainer (2).
10. Lightly grease the armature bearing with Lubriplate lubricant GM P/N 1050109, or the equivalent.
11. Install the armature bearing (2) to the gear shaft.
12. Install the armature (1) to the yoke (2).
13. Install the armature bushing to the armature.

Important: The brushes must contact the commutator end after installation.

14. Install the brush holder (1) to the yoke (2), connecting the brushes (4) to the brush holder.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

15. Install the spring washer (2) and the commutator end cover; secure with 2 bolts and 2 screws.

Tighten
Tighten the commutator end housing bolts to 8 N·m (71 lb in).

16. Install the solenoid.

### Solenoid Installation Procedure

1. Lightly grease the solenoid plunger with Lubriplate lubricant GM P/N 1050109, or the equivalent.
2. Install the solenoid to the drive housing, aligning the matchmarks (2).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the 2 screws.

Tighten
Tighten the solenoid (1) mounting screws to 7 N·m (62 lb in).

4. Install the field coil lead wire (2) and the retaining nut to the solenoid.
5. Install the starter to the vehicle. Refer to Starter Motor Replacement .