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1997 Ford Expedition Starter Motor REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 03-04-2011

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Starter Motor Removal WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. 1. Disconnect the battery ground cable. 2. Raise and support the vehicle; refer to Section 100-02 . 3. Remove the starter motor solenoid terminal cover (11N087). 4. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Disconnect the starter motor electrical connections. 1. Remove the nuts. 2. Remove the battery cable. 3. Remove the starter solenoid wire. 5. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Remove the (A) starter motor ground cable nut and the (B) starter motor ground cable. 6. Remove the starter. 1. Remove the two bolts. 2. Remove the starter. Installation WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. 1. Install the starter motor. 1. Position the starter motor. 2. Install the two bolts. 2. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the (A) starter motor ground cable and install the (B) starter motor ground cable nut. 3. NOTE: The 4.6L engine is shown; the 5.4L engine is similar. Connect the starter motor electrical connections. 1. Position the starter solenoid wire. 2. Position the battery cable. 3. Install the two nuts. 4. Install the starter motor solenoid terminal cover. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Connect the battery ground cable.

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2004-2006 Chevrolet Malibu Maxx Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning

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Filed Under (Chevrolet) by admin on 21-01-2011

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Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the models years and revise the information for Correction 2. Please discard Corporate Bulletin Number 06-02-32-007E (Section 02 – Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering

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1996 Volkswagen Golf STARTER DOES NOT CRANK ENGINE

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Filed Under (volkswagen) by admin on 30-06-2011

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1995-96 STARTING & CHARGING SYSTEMS Volkswagen Starters Cabrio, Golf III, GTI, Jetta III DESCRIPTION Starter is a brush type, series-wound electric motor with an overrunning clutch. Field frame is enclosed by commutator end frame and drive bushing, and carries pole shoes and field coils. A splined armature shaft drive end carries drive assembly. TROUBLE SHOOTING NOTE: ON-VEHICLE TESTING STARTER DOES NOT CRANK ENGINE 1) Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. With ignition switch in START position, measure voltage at spade terminal of starter solenoid. Reading should be at least 8 volts. If voltage is as specified, go to step 3). If voltage is not as specified, go to next step. 2) Measure voltage at ignition switch. If reading is at least 8 volts, check wiring between ignition switch and starter solenoid. If voltage is not as specified, replace ignition switch. 3) While operating starter, measure voltage at field (starter) terminal of starter solenoid. If reading is at least 8 volts, repair or replace starter. If reading is less than 8 volts, replace starter solenoid. NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION. On vehicles with automatic transmission, also check park/neutral switch. STARTER CRANKS TOO SLOWLY TO START ENGINE Ensure battery is fully charged. Ensure electrical and ground connections are clean and tight. If necessary, clean and tighten ground strap between transmission and body. DO NOT loosen ground strap on body. If starter still turns slowly, repair or replace starter. REMOVAL & INSTALLATION Removal & Installation 1) Disconnect negative battery cable. Support engine/transmission assembly with Support Beam (VW 10-222A) and Leg

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2006-2008 Chevrolet Avalanche No Movement When Transmission is Shifted to Drive or Third – Normal Operation When Shifted to Second, First or Reverse

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Filed Under (Chevrolet) by admin on 11-01-2011

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Models: 1982-2005 GM Passenger Cars and Light Duty Trucks 2006-2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006-2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006-2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006-2007 HUMMER H2 2006-2008 HUMMER H3 2006-2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag reserved. retaining rings (643). Refer assembly © 2010 General Motors. All rights

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2002 Kia Sportage Starter Motor: Service and Repair Removal and Installation

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Filed Under (KIA) by admin on 17-08-2010

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Removal 1. Disconnect negative battery cable. 2. Remove the upper two bolts from the intake manifold bracket. 3. Raise vehicle and support. 4. 5. 6. 7. 8. Remove the two bolts on the clutch release cylinder and push aside (M/T). Remove the lower two intake manifold bracket bolts. Remove intake manifold bracket. Remove the two upper starter bolts. Remove the lower starter bolt. 9. 10. 11. 12. Pull the starter from the clutch (M/T) / torque converter (A/T) housing and prop in place. Lower the vehicle. From above, disconnect the S-terminal connector. Remove nut and lock washer on B-terminal. 13. 14. 15. 16. Disconnect B-terminal. Raise and support vehicle. Push transmission wire harness aside. Remove starter. Installation 1. Place starter in engine well. 2. Lower vehicle. 3. Connect B-terminal wire. 4. Install washer and nut on B-terminal and tighten. 5. Connect S-terminal. 6. 7. 8. 9. 10. Lower intake manifold bracket into position and insert the two upper bolts. Raise and support vehicle. Place starter in position. Insert the two upper starter bolts. Insert lower starter bolt. NOTE:: The starter may require adjustment after installation. If required, rotate the starter slightly to provide proper clearance. 11. Tighten the three starter bolts. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 12. Insert lower bracket bolts and tighten. Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 13. Position clutch release cylinder and install bolts (M/T). Tighten the bolts to 27 – 40 lb-ft (37 – 54 N.m). 14. Lower vehicle.

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