Chevrolet 10465396 Starter,(Remanufacture)

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The steps for removing the starter in a 4WD vehicle are as follows:Disconnect the negative battery cable.

If the starter motor does not turn when the switch is operated, first check that the shift lever is in Neutral or Park (for automatic transmission) or that the clutch pedal is depressed (for manual transmission). Ensure that the battery is charged and that all cables are securely connected at the battery and starter solenoid terminals. If the starter motor spins but the engine does not crank, the overrunning clutch in the starter motor may be slipping and the motor will need to be replaced. If the solenoid clicks but the starter motor does not operate, the issue may lie with the battery, main solenoid contacts, or the starter motor itself. If the solenoid plunger cannot be heard when the switch is activated, the solenoid may be defective or there may be an open circuit. To check the solenoid, connect a jumper lead between the battery (+) and the "S" terminal on the solenoid. If the starter motor operates, the solenoid is fine and the problem may be with the ignition switch, neutral start switch, or wiring. If the starter motor still does not operate, the starter/solenoid assembly should be removed for disassembly, testing, and repair. If the starter motor cranks the engine at a slow speed, ensure that the battery is charged and all terminal connections are clean and tight. If the engine is partially seized or has the wrong viscosity oil, it may crank slowly. To further diagnose the issue, run the engine until it reaches normal operating temperature, then stop the engine, disconnect the coil wire from the distributor cap, and ground it on the engine. Connect a voltmeter positive lead to the starter motor terminal of the solenoid and the negative lead to the ground. Crank the engine and take voltmeter readings as soon as a steady figure is indicated, making sure not to let the starter motor turn for more than 15 seconds at a time. A reading of 9 volts or more, with the starter motor turning at normal cranking speed, is normal. If the reading is 9 volts or more but the cranking speed is slow, the motor is faulty. If the reading is less than 9 volts and the cranking speed is slow, the solenoid contacts are likely burned.

Check the starter cranking voltage and current draw from the battery while the starter is on the engine. Ensure that the battery is in good condition, with clean terminals and cables, and that the cold-cranking rating is suitable for the application. In extreme cold temperatures, warm the battery and engine block before testing.

Label and disconnect the wires from the terminals on the starter motor and solenoid.

Remove the mounting bolts and detach the starter.

Check the starter cranking voltage and current draw from the battery while the starter is on the engine. Ensure that the battery is in good condition, with clean terminals and cables, and that the cold-cranking rating is suitable for the application. In extreme cold temperatures, warm the battery and engine block before testing.

If the starter motor cranks the engine at a slow speed, ensure that the battery is charged and all terminal connections are clean and tight. Additionally, check if the engine is partially seized or has the wrong viscosity oil, as these factors can also cause slow cranking.

The steps for removing the starter in a 2WD vehicle are as follows: Disconnect the negative battery cable. Raise the front of the vehicle and support it securely on jack stands. On V6 models, remove the right front wheel for easier access. Remove the front exhaust pipe from the exhaust manifold. On 2.2L engines, take off the brace rod from the front of the engine to the bell housing. On certain models through 1999, remove the support bracket connecting the front of the starter to the block. If equipped, remove the starter heat shield. From underneath the vehicle, disconnect the solenoid wire and battery cable from the terminals on the solenoid. Remove the starter mounting bolts. Take out the starter motor, noting the location of any spacer shim(s), if present.

To adjust the shim for the starter, follow these steps: Remove the flywheel housing cover and inspect the flywheel or drive plate for signs of unusual wear. Measure the clearance between the top of the flywheel ring gear tooth and the bottom of the pinion tooth on the starter using a wire-type feeler gauge (round diameter). Normal clearance should be 0.01 to 0.06 inches. If the starter clearance is less than 0.02 inches and the starter whines after engagement, add a 0.04 shim to gain clearance (avoid using more than two shims). If the starter clearance is more than 0.06 inches and the starter whines during engagement, remove a 0.04 shim to gain clearance (avoid removing more than two shims). To install a shim, loosen the inside bolt, remove the outer bolt, and slide the shim between the engine and the starter without removing the starter from the engine block.

If the solenoid clicks but the starter motor does not operate, the issue may lie with the battery, main solenoid contacts, or the starter motor itself.

To adjust the shim for the starter, follow these steps: Remove the flywheel housing cover and inspect the flywheel or drive plate for signs of unusual wear. Measure the clearance between the top of the flywheel ring gear tooth and the bottom of the pinion tooth on the starter using a wire-type feeler gauge (round diameter). Normal clearance should be 0.01 to 0.06 inches. If the starter clearance is less than 0.02 inches and the starter whines after engagement, add a 0.04 shim to gain clearance (avoid using more than two shims). If the starter clearance is more than 0.06 inches and the starter whines during engagement, remove a 0.04 shim to gain clearance (avoid removing more than two shims). To install a shim, loosen the inside bolt, remove the outer bolt, and slide the shim between the engine and the starter without removing the starter from the engine block.

To diagnose slow cranking, run the engine until it reaches normal operating temperature, then stop the engine, disconnect the coil wire from the distributor cap, and ground it on the engine. Connect a voltmeter positive lead to the starter motor terminal of the solenoid and the negative lead to the ground. Crank the engine and take voltmeter readings as soon as a steady figure is indicated, making sure not to let the starter motor turn for more than 15 seconds at a time. A reading of 9 volts or more, with the starter motor turning at normal cranking speed, is normal. If the reading is 9 volts or more but the cranking speed is slow, the motor is faulty. If the reading is less than 9 volts and the cranking speed is slow, the solenoid contacts are likely burned.