SECTION 6D1-2 STARTING SYSTEM - V6 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will

consist of either seat belt pre-tensio ners and a driver’s side air bag , or seat belt pre-

tensioners and a driver’s and front passenger’s side air bags. Refer to CAUTIONS,

Section 12M, before performing any service operation on or around SRS

components, the steering mechanism or wiring. Failure to follow the CAUTIONS

could result in SRS deplo yment, resulting in possible p ersonal injury or unnecessary

SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). As this fuel in the

gaseous form is heavier than air, and in the interests of safety, the LPG fuel system

should be isolated by turning 'OFF' the manual service valve and then draining the

LPG service lin es, before any service wo rk is carried out on the vehicle. Refer to the

LPG leaflet included with the Owner's Handbook for details or LPG Section 2 for

more specific servicing information.

1. GENERAL INFORMATION

Figure 6D1-2-1

1.1 GENERAL DESCRIPTION

The starting system comprises the battery, starter

motor, ignition switch, neutral/back-up switch

(vehicles with automatic transmission), theft

deterrent engine crank inhibitor (function of theft

deterrent system) and related electrical wiring.

The starter motor is a series parallel wound, four

pole, four brush type with a planetary drive train.

The arm ature shaft is supported at each end by oil

absorbent sintered metal bushes pressed into the

commutator end cover and the inside of the

planetary drive shaft.

The planetary drive train consists of an internal

toothed ring gear (made from a high-grade

polyamide compound with mineral additives) and

keyed to the drive end housing, three gear wheels

which rotate on needle bearings and attached to

the planetary drive shaft. The gear wheels mesh

with gear teeth on the front end of the armature

shaft. The planetary drive shaft is supported at

each end by oil absorbent sintered metal bushes

pressed into the drive end housing and the inside of

the internal toothed gear. The arm ature rotates the

drive assembly at a reduced speed of

approximately 3.36:1.

These bearings require lubrication only at time of

overhaul.

The four brushes are supported by the brush holder

which is retained to the commutator end cover by

screws. Two brushes are grounded to the field coil

housing, and two are insulated from the housing

and connected to the field coils. The field coils are

held in place by the pole shoes which are attached

to the field coil housing by large diameter screws.

The field coils are connected to an insulated

terminal on the field coil housing through which

current is supplied to the starter motor from the

solenoid switch.

On the drive end housing, a plastic fork with plastic

bearing block is used to engage the drive as sem bly

with the flexplate/ring gear.

The drive assembly transmits cranking torque to

the flexplate/ring gear. To prevent the armature

from being driven at excessive speed by the

engine, an internal clutch allows the drive assem bly

pinion gear to rotate freely in relation to the

planetary shaft and armature when the engine

begins to operate.

Figure 6D1-2-2

Figure 6D1-2-3

1 Solenoid switch to drive end 12 Drive lever bearing 24 Brush holder spring

housing mounting screws 13 Sealing rubber 25 Thrust washer

2 Plunger 14 Planetary drive shaft 26 Commutator end cover

3 Return spring 15 Commutator front cover bush 27 Through bolt (standard)

4 Solenoid switch 16 Cover plate 28 Commutator end cover bush

5 ‘M’ terminal nut and washer 17 Field coil housing 29 Adjustment washers

6 Drive end housing bush 18 Field coil pole side screws 30 Horse shoe clip

7 Drive end housing 19 Pole shoe 31 Dust cover seal

8 Stud ring 20 Field coil and positive brushes 32 Felt pad

9 Stop ring retainer 21 Armature 33 Dust cover

10 Drive assembly 22 Brush holder & negative

brushes

11 Fork lever 23 Brush

2. SERVICE OPERATIONS

2.1 PERFORMANCE TESTING

The following tests involve the starter motor being

removed from the vehicle, refer to 2.2 STARTER

MOTOR - REMOVE in this Section.

SOLENOID SWITCH TESTS

Pull-In Test

1. Remove nut and washer from solenoid switch

short threaded ter m inal ('M' term inal) . Rem ove

field coil braided cable and terminal from

threaded terminal.

2. Using suitable test leads and 12 volt battery,

connect as shown in Figure 6D1-2-4. Check

that drive assembly moves outward.

If drive assembly does not move, replace

solenoid switch as described in this Section.

Figure 6D1-2-4

Hold-In Test

1. With battery connections to starter motor and

solenoid switch as shown for Pull-In Test,

disconnect negative lead from solenoid switch

short threaded terminal ('M' terminal).

2. Check that drive assembly remains outward.

If drive assembly returns inward, replace

solenoid switch as described in this Section.

Figure 6D1-2-5

Drive Assembly Return

1. With battery and connections to starter motor

and solenoid switch as at end of Hold-In Test,

disconnect negative lead from drive end

housing.

2. Check that drive assembly returns inward.

If drive assembly does not return, replace

solenoid switch as described in this Section.

Figure 6D1-2-6

NO LOAD TEST

The drive assembly pinion should be checked for

freedom of operation by turning it on the planetary

drive shaft. The planetary drive and armature

should be check ed f or f reedom of r otation by prying

the drive assem bly pinion with a screwdriver. If the

planetary drive and armature do not rotate freely,

the starter motor should be disassembled

immediately. However, if the planetary drive and

armature do rotate freely, the starter motor should

be given a NO LOAD test before disassembly.

Clamp starter motor securely to a test bench and

make connections as shown. Close the switch and

compare the rpm, current and voltage readings with

the following specifications.

STARTER MOTOR SPEED

(ARMATURE RPM) 5300 RPM

STARTER MOTOR CURRENT 125 AMPS

TERMINAL VOLTAGE 11.5 VOLTS

If the NO LOAD test indicates that the starter

motor is defective, refer to 3. DIAGNOSIS in this

Section for probable cause of starter motor fault.

Figure 6D1-2-7

2.2 STARTER MOTOR

REMOVE

1. Disconnect battery earth lead.

2. Jack up front of vehicle and support on safety

stands. For location of jacking locations, refer

to Section OA GENERAL INFORMATION.

3. Remove starter motor to cylinder block

mounting bolts.

Lower starter motor and out as far as poss ible

so as to gain access to wiring harness

connections at starter motor solenoid switch.

Figure 6D1-2-8

4. Pull wiring harness connector from solenoid

switch '50' terminal.

5. Remove nut, washer and battery lead from

solenoid switch '30' (B+) terminal.

Figure 6D1-2-9

6. Withdraw starter motor.

Figure 6D1-2-10

REINSTALL

Installation of the starter motor is the reverse of

removal procedures, noting the following points:

1. Ensure that all fasteners are tightened to the

correct torque specification.

STARTER MOTOR TO CYLINDER

BLOCK MOUNTING BOLT TORQUE

SPECIFICATION 40 - 60 Nm

STARTER MOTOR '30' (B+)

TERMINAL NUT

TORQUE SPECIFICATION 9.8 - 11.3

. Nm

2. Check starter motor operation.

DISASSEMBLE

1. Remove nut and washer from solenoid switch

short threaded ter m inal ('M' term inal) . Rem ove

field coil braided cable and terminal from

threaded terminal.

Figure 6D1-2-11

2. Scribe an aligning mark on drive end housing

and solenoid switch housing as an aid for

reassembly.

Remove the thr ee solenoid switch to drive end

housing mounting screws.

NOTE:

It may be necessar y to loosen the m ounting s crews

using an im pact driver. Ens ure to only lightly tap on

the impact driver so as not to damage the drive end

housing.

Figure 6D1-2-12

3. Pull solenoid switch from drive end housing,

taking care not to lose the plunger return

spring. (Plunger will slide out from solenoid

switch and remain attached to drive assembly

fork lever).

4. Remove solenoid switch plunger by lifting up

and then unhooking front from drive assembly

fork lever.

Figure 6D1-2-13

5. Scribe an aligning mar k on drive end housing,

field coil housing and commutator end cover

as an aid for reassembly.

6. Loosen and remove the two through bolts

securing the commutator end cover and field

coil housing to the drive end housing.

Figure 6D1-2-14

7. Keeping the sealing rubber seated in the drive

end housing, remove the commutator end

cover, field coil housing and armature an

assembly from the drive end housing.

Figure 6D1-2-15

8. Remove the scr ews secur ing the dust cover to

the commutator end cover and brush holder.

Remove horse shoe clip and adjustment

washer/s from commutator end of armature.

Figure 6D1-2-16

9. While holding field coil braided cable seal to

the field coil housing, pull commutator end

cover from field coil housing.

Figure 6D1-2-17

10. Carefully bend back all the brus h holder spr ing

retaining tags, remove all springs and the

positive brushes. Remove the brush holder

from the armature's commutator.

Figure 6D1-2-18

11. Remove the armature from the field coil

housing. Rem ove the armature to com mutator

end cover thrust washer. (The washer may

either be on the end of the armature or

attached to the inside of the commutator end

cover).

Figure 6D1-2-19

12. Remove the sealing rubber from drive end

housing, noting how it is installed.

13. Remove the drive assembly with fork lever and

planetary drive assembly from the drive end

housing.

14. Remove fork lever from drive assembly by

spreading fork lever arms and disengaging

from drive assembly pivots.

Figure 6D1-2-20

15. Clamp the end of the planetary drive shaf t in a

vice fitted with soft jaws. Prise the stop ring

retainer towards the drive assembly using two

screwdrivers pivoting on vice jaws and levering

against stop ring retainer.

As an alternative, use Bosch Tool Nos. KDAL

5047 and KDAL 5028.

16. Remove planetary drive shaft and drive

assembly from the vice.

17. Using a pair of circlip pliers, expand the stop

ring and slide it from the planetary drive shaft,

taking care not to scratch or damage the

planetary drive shaft.

18. Before attempting to remove the drive

assembly, remove any burrs on the planetary

drive shaft, particularly in the area of the stop

ring groove using a fine file. This step is

necessary so as to prevent damaging the drive

assembly to planetary drive shaft bushing

when removing the drive assembly.

Slide the stop ring retainer and drive assem bly

from the planetary drive shaft.

Figure 6D1-2-21

19. Prise the cover plate from the ring gear.

Figure 6D1-2-22

20. Remove planetary drive shaft to ring gear

retaining clip and washer.

Figure 6D1-2-23

21. Push planetary drive shaft from ring gear and

separate components.

Figure 6D1-2-24

CLEANING AND INSPECTION

With the starter motor completely disass embled, all

components should be cleaned and thoroughly

inspected.

W ash all c omponents exc luding the armature, field

coils, brushes, solenoid switch and drive assembly

in a suitable cleaning agent. Clean these

com ponents with clean shop rags and com pressed

air.

CAUTION:

Do not clean armature or field coils with

cleaning solvent as damage to the insulation

could occur.

Washing the drive assembly in solvent will

wash out all the lubricant, causing the drive

assembly to slip.

WARNING:

CLEAN ALL PARTS OTHER THAN THOSE

PREVIOUSLY NOMINATED USING A NON

VOLATILE OR LOW INFLAMM ABLE AGENTS IN

A WELL VENTILATED AREA. IT IS IMPORTANT

THAT ALL PARTS ARE THOROUGHLY DRIED

BEFORE ASSEMBLY, TAKING CARE NOT TO

BREATH IN ANY VAPOURS. OBSERVE THE

SAFETY REGULATIONS AND PRECAUTIONS

ISSUED BY THE MANUFACTURER OF THE

CLEANING AGENT IN USE.

COMPONENT CHECKING

FIELD COILS

1. Connect a 12 volt powered DC test lamp

between field coil braided c able term inal and a

positive brush. If the field coil circuit is

serviceable, the lam p will illum inate to indicate

continuity.

Repeat the procedure on the other positive

brush.

Figure 6D1-2-25

2. Ensure brushes are not touching the field coil

housing. T est the f ield coils f or shor t circ uits to

earth using an insulation tester with a

minimum AC voltage of 40 volts.

NOTE:

An ohmmeter cannot be used to check the field

coils for shor t circuits to ear th as the output voltage

from the ohmmeter does not place sufficient

'stress' on the field coils to give an accurate test

result.

Figure 6D1-2-26

3. Visually inspect field coil windings for signs of

insulation breakdown and/or burns

(overheating). If this condition is present, the

field coil must be replaced as follows:

NOTE:

This starter motor uses an interlocking joint in the

field coil hous ing, therefor e care mus t be ex ercis ed

whenever clamping the field coil housing in a vice.

Ensure the vice is fitted with soft jaws and do not

over tighten as it will distort the housing.

It is recommended that a mandrel having a

diameter of 52.8 + 0.2 - 0.1 mm x 30 mm long be

inserted inside the field coil housing, between the

field coil pole shoes. This step is necessary so as

to support the field coil housing in the vice whilst

the field coil pole shoe screws are removed.

a. Place mandrel inside field coil housing

and clamp the housing in a vice with soft

jaws.

Figure 6D1-2-27

b. Using a Posidriv No. 3 bit, loosen and

remove the four field coil pole shoe

screws.

Figure 6D1-2-28

c. Remove field coil housing from vice and

pull the field coil out from the brush end of

the housing complete with mandrel and

pole shoes. Separate mandrel, field coils

and pole shoes.

Figure 6D1-2-29

d. Insert the pole shoes into the new field

coil and place inside the field coil

housing. Install the pole shoe screw and

leave finger tight.

e. Insert mandrel inside field coil housing to

support pole shoes and clamp in vice with

soft jaws.

f. Tighten field coil pole shoe screws to the

correct torque specification.

FIELD COIL POLE SHOE SCREW

TORQUE SPECIFICATION 25

. Nm

g. Recheck field coils using insulation

tester.

FIELD COIL RESISTANCE 1 Megohm

or greater

ARMATURE INSULATION TEST

Check armature insulation resistance to earth

using a 'meggar' or similar tester. A reading of 1

Megohm or greater should be expected.

ARMATURE SHORT CIRCUIT TEST

Test armature for short circuits on a growler.

1. Place the armatur e on a gr owler and switch on

growler. Hold a hacksaw blade approximately

6 mm above armature core and rotate

armature.

2. If the hacksaw blade vibrates, undercut

between the commutator segments (to a depth

of approximately 0.8 mm) using a suitable

small file, then re-check armature.

3. If hacksaw blade still vibrates, the armature is

short circuited and must be replaced.

Figure 6D1-2-30

ARMATURE CONTINUITY TEST

An open circuit in the armature winding may

sometimes be detected by examining the

commutator for evidence of burnt or darkened

segments. A burnt or darkened commutator

segm ent is c aused by an arc for med every time the

segment connected to the open circuit winding

passes under the brush.

If a segment has been burnt or is darkened,

replace armature.

Test the armature for continuity on a growler.

1. Place the armatur e on a gr owler and switch on

growler.

2. Using a voltmeter, measure the voltage

induced in the armature windings by touching

probes onto two adjacent commutator

segments.

NOTE:

To obtain maximum voltage reading, choose two

segments which are approximately 45 degrees

from the top of the commutator.

3. Rotate the armature in the growler so that the

next two commutator segments are in the

same position as the previous two segments

in step 2. Measure voltage across adjacent

commutator segments.

4. Repeat step 3 until voltage reading across all

adjacent sets of commutator segments has

been measured.

The voltage reading ac ross eac h adjacent pair

of commutator segm ents should be the same,

provided each adjacent set of segments are

positioned in the growler in the same location.

If a voltage reading across any adjacent set of

segments differs from the remainder, the

armature winding has an open circuit, and the

armature must be replaced.

Figure 6D1-2-31

COMMUTATOR SURFACE

Check commutator and armature laminations for

out-of-round.

If the armature is otherwise satisfactory but

commutator is worn, burnt, out-of round, or has

high insulation between the segments, the

commutator should be machined.

If the out-of-round check on the armature

laminations is greater than the specified value,

replace the armature.

Figure 6D1-2-32

COMMUT ATOR MAXIMUM

PERMISSIBLE OUT-OF-ROUND 0.1

MAXIMUM PERMISSIBLE OUT-OF-

ROUND OF ARMATURE

LAMINATIONS 0.5 mm

NOTE:

Replace the armature if the commutator diameter is

below the dimension given in the following chart.

COMMUT ATOR MINIMUM 31.2

DIAMETER mm

When machining the armature, it must not be held

by the laminations. The armature must be held at

the drive end and supported at the c ommutator end

bearing surface.

It is recommended that the commutator be turned

in two stages, that is pre-turning and finish turning. Figure 6D1-2-33

Finish cut the armature using a fine tool. The cut

should be no more than 0.03 mm. After turning,

polish surface if necessary using 500-600 grade

emery cloth and then brush out the commutator

segment slots using a stiff brush.

Check the diam eter of the com mutator. If less than

the specified value, replace the armature.

Figure 6D1-2-34

Check depth of insulating mica from commutator

surface. If depth is less than 0.2 mm, undercut

using a file to a depth of 0.5 to 0.8 mm.

CAUTION:

It is important to use dust extraction when

undercutting commutators.

After under cutting, car efully clean all dirt and debr is

from commutator segment slots and lightly polish

commutator with fine emery cloth to remove any

burrs left by the undercutting operation. Clean

commutator and armature thoroughly using

compressed air.

Figure 6D1-2-35

BRUSHES

Check brush holder springs for breakage and

corrosion, replace as necessary.

MINIMUM BRUSH LENGTH 7 mm

Ensure that brushes slide sm oothly in their holders,

brush connec tions are good and brushes are clean

and not chipped.

Check brush length. If any brush is below

specification, replace the complete brush set and

machine commutator if necessary.

If necessary, replace brushes as follows:

Figure 6D1-2-36

POSITIVE BRUSHES

1. Cut the brush lead approximately 4 mm up

from the f ield c oil connec ting s tr ap and disc ar d

brush.

2. Clean the remains of brush lead on field coil

connecting strap and 'tin' the lead with 60/40

resin cored solder.

3. Hold the new brush lead in position on the pre-

tinned cut-off lead using a pair of pointed nose

pliers. Solder new brush lead to cut-off lead.

NOTE:

When soldering the new brush lead into place,

ensure that the solder does not run up the lead by

capillary action. Should this happen, it will make the

lead too inflexible and not allow correct brush

movement and/or cause fouling during reassembly.

Figure 6D1-2-37

NEGATIVE BRUSHES

1. Before removing the old brushes, special

attention must be paid to the direction of the

brushes in the way they are soldered to the

plate.

2. Cut old brush lead off at lowest point of the

flexible braded section.

3. Clean remaining brush lead on brush holder.

'Tin' rem aining br us h lead on brus h holder with

60/40 resin cored solder.

Figure 6D1-2-38

3. Hold the new brush lead in position on the pre-

tinned cut-off lead using a pair of pointed nose

pliers, noting brush lead direction as per step

1. Solder new brush lead to cut-off lead.

NOTE:

When soldering the new brush lead into place,

ensure that the solder does not run up the lead by

capillary action. Should this happen, it will make the

lead too inflexible and not allow correct brush

movement and/or cause fouling during reassembly.

Figure 6D1-2-39

BRUSH HOLDER ASSEMBLY

Using an ohmmeter, check insulation between the

positive brush holders and the brush holder

assembly base. If continuity exists, replace holder

assembly.

Figure 6D1-2-40

Check continuity between negative brushes and

holder assembly base. If continuity does not exist,

replace the brush holder.

Check condition of the brush holder spring retaining

tags. If any tags are weak, broken or there is any

sign of fatigue from being bent back, replace the

brush holder assembly.

Figure 6D1-2-41

DRIVE ASSEMBLY CHECK

Inspect drive assembly pinion gear for burrs and

worn or chipped teeth.

Check the operation of the pinion. The pinion gear

should rotate free and smooth in relation to the

drive assembly pinion housing when turned in a

clockwise direction, but will not rotate when turned

in a counter-clockwise direction.

Replace the drive assembly if out of specification,

or if pinion gear is damaged or broken, inspect

flexplate/ring gear teeth and replace as necessary,

refer to Section 6A1-1 ENGINE MECHANICAL -

V6 ENGINE.

Examine the pinion internal bush for wear or

scoring, if in any doubt, replace the drive assembly.

Inspect fork lever contact surfaces and pivots.

Replace fork lever if worn.

Figure 6D1-2-42

BUSHES

Check the fit of the armature shaft in the

commutator end cover and the front end of the

planetary drive shaft in the drive end housing.

If bushes are exc essively worn, the starter motor is

likely to operate inefficiently and/or the armature

may foul on the field coils.

To remove the bushes, support the commutator

end cover or drive end housing (as appropriate),

and carefully tap bush out using a suitable sized

mandrel.

NOTE:

If new bushes are to be installed, they must be

soaked in clean engine oil overnight. If time does

not perm it over night s oaking, oil can be forc ed into

the bush by placing a thumb over end of the bush

and filling the bush cavity with oil.

Using the other thumb over the opposite end of the

bush, press bush firmly compressing the oil

between thumbs until the oil is visible on the outer

surfaces of the bearing.

To install new bushes, press or tap into position

with a suitable shouldered mandrel.

Do not ream bushes after they have been installed

as the self-lubricating qualities of the bush will be

diminished.

SOLENOID SWITCH TESTING

Inspect the solenoid switch for any external

damage.

Install return spring and plunger to solenoid switch.

Depress plunger and release it. T he plunger s hould

return quickly to its original position. If the plunger

sticks in the switch bore, replace solenoid switch

assembly.

PULL-IN WINDING TERMINALS 50

RESISTANCE AND M

HOLD-IN WINDING TERMINAL 50 AND

RESISTANCE SOLENOID SWITCH

HOUSING Figure 6D1-2-43

Check the solenoid switch windings dc resistances

using an ohmmeter acr os s the ter minals nominated

in the following chart.

Figure 6D1-2-44

Replace solenoid switch if resistance readings are

not to specification

PULL-IN WINDING 0.248 - 0.281 Ohms

RESISTANCE @ 20° C

HOLD-IN WINDING 1.16 - 1.30 Ohms

RESISTANCE @ 20° C

Figure 6D1-2-45

TESTING 'PULL-IN' AND 'HOLD-IN' VOLTAGES

During the following solenoid switch 'pull-in' and

'hold-in' checks, the solenoid switch must be held

vertically, i.e. with the plunger uppermost. It is

recommended that a rubber band be fitted around

the plunger and solenoid switch housing to prevent

the plunger from flinging out during testing.

Using a power supply capable of supplying 30

amps, set the voltage to 3.0 volts. A battery and a

variable resistor may also be used.

Connect the solenoid to the power supply as shown

in Fig. 6D1-2-46.

Connect a 12 volt test lamp between solenoid

switch terminal '30' and +12 volt supply. Also,

connect a voltmeter between solenoid switch

terminal 50 and earth.

Fully press in solenoid plunger until test lamp

illuminates. Allow the plunger to spring out by

approximately 8 - 10 mm and hold in this position.

NOTE:

The test duration for the following 'pull-in' voltage

check should be no more than two seconds.

Slowly increase the voltage on terminal '50' until the

plunger pulls in, noting the voltmeter r eading. At the

same time, the test lamp must be fully illuminated

(check of solenoid switch main contact continuity)

Voltage reading should be as specified in the

following chart.

PULL-IN VOLTAGE TEST 3.0 - 6.5

SPECIFICATION VOLTS

Figure 6D1-2-46

Set the power supply to 12 volts and connect the

positive lead to solenoid switch terminal '50'.

Connect the negative lead to the solenoid switch

housing. Press the plunger in f ully. It should r em ain

held in by the solenoid's hold-in winding.

Decrease the voltage until the winding will no

longer hold the plunger, noting the voltmeter

reading.

Voltage reading should be as specified in the

following chart.

HOLD-IN VOLTAGE TEST 0.2 - 2.0

SPECIFICATION VOLTS

Press the plunger until the solenoid switch contac ts

close (indicated by test lamp illuminating).

It should be possible to depress the plunger into the

solenoid switch housing a further 1 mm or more. If

less than 1 mm is achieved, the solenoid switch

must be replaced.

Figure 6D1-2-47

A 24 volt supply is required for this test.

Attach positive supply lead to solenoid switch

terminal '30' (main battery supply input) and

negative lead to solenoid switch housing.

Press the plunger in fully and then release. The

plunger should return to its rest position by the

action of the return spring. If it does not, the

windings have interwinding short circuits.

W hen the solenoid s witch is connected in this way,

the windings are differentially compounded, that is

their fields are in opposition to each other.

At end of solenoid switch testing, remove rubber

band retaining the plunger and return spring in the

solenoid switch housing.

Figure 6D1-2-48

REASSEMBLE

Reassembly of the starter motor is the reverse of

the disassembly procedure, noting the following

points:

1. Lubricate drive end housing, commutator end

cover and drive assembly to planetary drive

bushes with clean engine oil.

2. Lightly coat helix on armature shaft, helix

inside drive assembly, inside of ring gear and

armature to commutator end cover thrust and

adjustment washers with Molybdenum

Disulphide grease (Holden Specification HN

1271 or equivalent). Pack som e grease inside

of commutator end cover dust cover.

3. Check armature end play by installing

armature to commutator end cover thrust

washer, assembling armature to commutator

end cover. Install adjustment washer and

horse shoe c lip. Us ing f eeler gauges , meas ure

clearance between adjustment washer and

commutator end cover. If necessary, adjust

armature end float to specification using

adjustm ent washers between com mutator end

cover and horse shoe clip.

ARMATURE END PLAY 0.05 - 0.3

SPECIFICATION mm

W hen end f loat is corr ect, rem ove c omm utator end

cover from armature.

Figure 6D1-2-49

4. To install the stop ring retainer over the stop

ring, clamp the fr ont end of the planetary drive

shaft in a vice fitted with soft jaws. Slide the

stop ring retainer up to the s top r ing and fit two

open end spanners in between the stop ring

retainer and the drive assembly gear.

Using a pin punch and ham mer, lightly tap the

stop ring into the planetary drive shaft groove.

Then push down on the two spanners to force

the stop ring retainer over the stop ring.

Figure 6D1-2-50

5. Slide drive assembly up and down planetary

drive shaft ensuring that it moves freely.

Check drive assembly clutch action.

6. Expand fork lever arms and position over drive

assembly pivots.

7. Install planetary drive shaft into the opening of

the drive end housing, aligning the flat on the

ring gear outer sur face toward the opening f or

the solenoid switch. Slide the assembly into

position allowing the fork lever pivot to enter

the drive end housing.

Install the sealing rubber behind the pivot,

aligning the 'V' groove with the mating raised

groove on the pivot and thick section toward

the drive end housing solenoid switch

opening.

8. Assemble armature into the field coil housing

with commutator exposed at rear of housing.

Install brush holder over commutator, aligning

the positive brush holders with the brush lead

connections on the field coils.

Position all brushes into their respective

holders, ensuring that the brush leads locate

into the slots on the side of eac h holder. Ins tall

brush springs and carefully bend over the

brush holder spring retaining tags.

9. Ensure that armature to commutator end

cover thrust washer is installed on armature.

Assem ble comm utator end cover, aligning the

field coil braided cable grommet with the

cutout in the commutator end cover.

Install correct adjustment washers and horse

shoe clip.

Assemble dust cover onto commutator end

cover and align screw holes in dust cover with

commutator end cover and brush holder.

Install dust cover securing screws and tighten

to the correct torque specification.

DUST COVER SECURING SCREW

TORQUE SPECIFICATION 1.4 - 2.0

10. Assemble the field coil housing to the drive

end housing, aligning the cutout in the field

coil housing with the sealing rubber in the

drive end housing. Carefully fit the armature

into the planetary drive. It may be necessary to

rotate the pinion gear slightly to enable the

armature gear to engage the planetary gears

(do not force entry).

11. Install through bolts and tighten to the correct

torque specification.

THROUGH BOLT

TORQUE SPECIFICATION 7.5

12. Lightly coat solenoid switch plunger with

Molybdenum Disulphide grease (Holden

Specification HN 1271 or equivalent).

NOTE:

Do not under any circumstances allow grease on

the rear face of the plunger. If too much grease is

applied, it may enter the contact chamber of the

solenoid switch and cause contact problems.

13. Assemble return spring and plunger to

solenoid switch.

Pull pinion gear forward and assemble

solenoid switch assembly to drive end

housing, ensuring that plunger hooks over

drive assembly fork lever.

Ensure that solenoid switch housing is

correctly aligned with drive end housing, that is

with terminal 30 facing away from field coil

housing. Install and tighten solenoid switch to

drive end housing mounting screws to the

correct torque specification.

SOLENDOID SWITCH TO DRIVE END

HOUSING MOUNTING SCREW

TORQUE SPECIFICATION 5.5 Nm

14. Install field coil braided cable and terminal

over solenoid switch lower threaded terminal.

Install washer and nut to threaded terminal

and tighten to the correct torque specification.

THREADED TERMINAL NUT

TORQUE SPECIFICATION 9

15. With the starter motor reassembled, a NO

LOAD test should be conducted, refer to

2.1 PERFORMANCE TESTING in this

Section.

Failure of the starter motor to perform

according to the NO LOAD specification may

be due to tight or dirty brushes or high

resistance connections. Rectify any faults

found.

3. DIAGNOSIS

Many starting problems can be categorised within the following classifications:

1. The starter motor will not crank the engine.

2. The engine will crank at normal speed, but will not start.

3. The starter cranks the engine very slowly.

If the engine is cranked over by the starter motor at the normal speed, but will not start, the problem is in the

ignition system, fuel system or engine, rather than a fault in the starting system.

Before removing the starter motor, when investigating a starting problem, follow the procedures outlined in the

accompanying diagnostic charts.

SYMPTOM PROBABLE FAULT

A. Speed, torque and current low. A. High resistance in motor. Check field to

terminal connection, condition of

brushes and their connections and

check for dirty brushes or burnt

commutator.

B. Speed and torque low, current high. B. Tight or worn bearings, bent armature

shaft, insufficient end play, armature

fouling pole shoe, short-circuited

armature, earthed armature or field coil.

C. Speed and current high, torque low. C. Short circuited windings in field coil.

D. Armature does not rotate. No current. D. Open circuited armature, field coils or

solenoid. If commutator is badly burned,

there may be poor contact between

brushes and commutator, owing to

excessively worn or sticking brushes.

E. Armature does not rotate. High current. E. Earthed field winding or short-circuited

solenoid switch. Armature physically

prevented from rotating.

F. Excessive brush movement causing arcing

at commutator. F. Low brush spring tension, worn or out-

of-round commutator, 'thrown' or high

segment on commutator, or insulation

protruding between segments.

G. Excessive arcing at commutator. G. Defective armature windings, sticking

brushes or dirty commutator.

H. Armature rotates but pinion does not mesh

with ring gear. H. Pinion bearing fouled, burred, damaged

flexplate/ring gear or broken pinion

teeth.

VT series Commodores are fitted with a timed security override. Turn ignition switch to the ‘ON’ position and

security override will occur in two hours. (Theft alert indicator LED stops)

If engine now cranks then fault is in the theft deterrent system. Refer to Section 12F THEFT DETERRENT

SYSTEM.

If engine still does not crank then continue with this diagnostic procedure.

NO CRANKING, NO SOUND FROM SOLENOID:

STEP ACTION RESULT YES NO

1. • Turn Headlamps and

Dome l amps On, Turn

Ignition to Start

Position.

Lamps

Dim Go to Step 2 Go to Step 3

2. • Check battery

• Charge battery

• Check generator

• Check cranking

voltage at battery posts

• Check current draw

Is 9.6

volts

present

Go to Step 7 Test battery.

If OK repair

Starter

3. • Turn on radio Operate

OK Go to Step 4 Go to Step 6

4. • Check voltage at

Solenoid Switch

terminal ‘50’.

Is 7.0

volts

present

Repair Starter Go to Step 5

5. • With Key in Start

Position, Check at

Ignition terminal ‘50’.

Is 7.0

volts

present

Repair wiring

Ignition Switch

Starter Motor

Replace Ignition

Switch

6. • Check engine main

wiring harness fusible

link and ignition

connections

7. • Check voltage from

engine block to Neg.

post. Key in start

position. (Pos. lead on

block)

Is 0.5

volts or

present

Clean and tighten

negative cable

conn. And/or

replace cable

Go to Step 8

8. • Check cranking

voltage at starter “B”

terminal

Is 9.0

volts

present

Check fuse and

engine to M.W.H.

connectors

Clean and tighten

positive cable

conn. And/or

replace cable

SLOW CRANKING, SOLENOID CLICKS OR CHATTERS:

Check : Battery state of charge. Refer to Section 12A BATTERY A ND CABLES.

Visual condition of battery cables and connections.

If battery needs charging, carry out generator and battery drain check, charge battery and recheck cranking. If

trouble has not been found proceed.

Remove engine fuse link from engine compartment fuse housing. This prevents fuel injection and ignition during

engine cranking. Make all voltmeter readings with ignition key in start position.

STEP ACTION RESULT YES NO

1. • Measure cranking

voltage at battery

terminal posts

Is 9.6

volts or

present

Go to Step 2 Go to Step 3

2. • Measure voltage from

battery negative

terminal to engine

block. (positive lead on

block)

Is 0.5

volts or

present

Repair negative

cable and

connections

Go to Step 4

3. • Charge and load test

battery Is battery

OK Repair Starter Replace battery

4. • Measure voltage at

solenoid switch ‘30’

(B+) terminal, clean

and tighten

connections at starter

Is 9.0

volts or

present.

Repair starter Go to Step 5

5. • Clean and tighten

positive cable

connections.

• If OK replace cable

This procedure is designed for use on engines and batteries at room temperature or normal operating

temperatures. It also assumes there are no engine defects which could cause cranking problems. To use it under

other conditions might result in misdiagnosis.

4. SPECIFICATIONS

Type Bosch DV. Four pole, four brush

with planetary drive train

Rotation (drive end view) Clockwise

Number of pinion teeth 9

No load test:

Maximum current 125 amps at 11.5 Volts

rpm 5300

Lock test:

Maximum current (including solenoid) 740 amps

Volts 4 volts

Torque 20 Nm

Solenoid Test Solenoid detached from

starter motor:

Pull in voltage 7.8 volts @ 20°C

Hold-in winding resistance 1.16 - 1.3 Ohms @ 20°C

Pull-in winding resistance 0.248 - 0.281 Ohms @ 20°C

Armature end play 0.05 - 0.30 mm

Armature laminations permissible out-of-round 0.5 mm

Commutator:

Maximum permissible out-of-round 0.1 mm

Diameter - New 32.3 mm

Minimum diameter 31.2 mm

Depth of undercut 0.8 mm

Brushes:

Minimum length 7 mm

Field coil winding resistance 1 Megohm or greater

5. TORQUE WRENCH SPECIFI CATIONS

Through bolts 7.5

Pole screws 25

Solenoid attaching bolts 5.5

'30' terminal nut 9.8 - 11.3

'50' terminal nut 9.0

'Dust cover securing screws 1.4 - 2.0

Starter motor to cylinder block

mounting bolts 40 - 60