battery CHEVROLET DYNASTY 1993 Manual PDF

STARTER INDEX
page page
General Information ........................ 4
Neutral Starter and Back-Up Switch ........... 8
Starter Component Replacement .............. 5
Starter Interlock Switch: Clutch Pedal Mounted/ Manual Transmission Only ................. 7 Starter Motor Replacement
.................. 4
Starting System ........................... 4
Supply Circuit and Control Circuit ............. 4
GENERAL INFORMATION
This section will cover Starter replacement and
service procedures only. For starter diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics.
STARTING SYSTEM
The starting system has:
² Ignition switch
² Starter relay
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Wiring harness
² Battery
² Starter motor with an integral solenoid
BOSCH STARTERS
²A Bosch permanent magnet starter motor is avail-
able on 2.2L, 2.5L and 3.0L engines on all vehicles.
A planetary gear train transmits power between
starter motor and pinion shaft. The fields consist of
six permanent magnets.
NIPPONDENSO STARTERS
² A Nippondenso reduction gear-field coil starter
motor is available on 3.0L, 3.3L and 3.8L engines.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
Both starter systems consist of two separate cir-
cuits:
² A high amperage supply to feed the starter motor.
² A low amperage circuit to control the starter sole-
noid. For additional information on starter motor supply
and control circuits, refer to Group 8A, Battery/Start-
ing/Charging Systems Diagnostics.
STARTER MOTOR REPLACEMENT
BOSCH STARTERÐ2.2L/2.5L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Raise vehicle. (3) Remove heat shield clip from the starter and
heat shield is clipped to starter (Fig. 2). For easier
servicing, do not remove the wiring from starter at
this time.
(4) Remove two bolts and one nut attaching starter
to engine (Fig. 3). (5) Remove starter/starter solenoid assembly from
engine. Position the starter to gain access to the wir-
ing connectors. (6) Disconnect the positive battery cable and wir-
ing at the starter. (7) Remove the starter from vehicle.
Fig. 1 Remove or Install Battery Cable
Fig. 2 Starter Heat ShieldÐ4 Cylinder Engines
8B - 4 BATTERY/STARTER/GENERATOR SERVICE Ä

(8) For installation, reverse above procedures.
Clean corrosion/dirt from the cable and wire termi-
nals before installing wiring to the solenoid.
BOSCH OR NIPPONDENSO STARTERÐ3.0L/ 3.3L/3.8L ENGINE
(1) Disconnect NEGATIVE battery cable (Fig. 1).
(2) Raise vehicle.
(3) Remove three starter attaching bolts at engine/
transaxle (Fig. 4).
(4) Remove the two wire connector terminal nuts
and remove wiring connector (Bosch, Fig. 5) (Nippon-
denso, Fig. 6 or 7). (5) Remove starter from vehicle (Bosch, Fig. 8)
(Nippondenso, Fig. 9). (6) For installation, reverse above procedures.
Clean corrosion/dirt from the cable and wire termi-
nals before installing wiring to the solenoid.
STARTER COMPONENT REPLACEMENT
Caution: When servicing the starter assembly off
the vehicle, do not clamp the starter to a vice. In-
ternal damage may result.
Fig. 3 Bosch StarterÐ2.2L/2.5L Engine
Fig. 4 Remove or Install Attaching BoltsÐTypical
Fig. 5 Wire Terminal ConnectionsÐBosch Starter
Fig. 6 Wire Terminal ConnectionsÐ3.0L EngineÐNippondenso Starter
Fig. 7 Wire Terminal ConnectionsÐ3.3L/3.8L EngineÐNippondenso Starter
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 5

NIPPONDENSO STARTER GEAR AND CLUTCH
REMOVAL AND INSTALLATION (1) Remove the two gear housing attaching screws
and separate the gear housing from the solenoid
housing (Fig. 10). The pinion gear, pinion gear bear-
ing, and drive gear will be loose between the solenoid
housing and gear housing (Fig. 11). When reinstall-
ing pinion gear and bearing, wipe with a clean rag
and coat with lightweight high temperature wheel
bearing grease. Place the lubricated bearing and
gear over the bearing shaft in the gear housing (Fig.
12). (2) Remove the starter gear and clutch assembly
from the solenoid housing (Fig. 13). (3) For assemble, reverse above procedures.
BOSCH STARTER SOLENOID REPLACEMENT
(1) Remove field terminal nut (Fig. 14).
(2) Remove field terminal (Fig. 15).
(3) Remove field washer (Fig. 16). (4) Remove three solenoid mounting screws (Fig.
17). (5) Remove the solenoid from the starter assembly.
(6) For installation, reverse above procedures.
Fig. 8 Remove/Install StarterÐBoschÐTypical
Fig. 9 Remove/Install
StarterÐNippondensoÐTypical
Fig. 10 Remove or Install Gear Housing
Fig. 11 Remove or Install Drive and Pinion Gears
Fig. 12 Lubricate and Install Pinion Gear Bearing
8B - 6 BATTERY/STARTER/GENERATOR SERVICE Ä

BOSCH STARTER GEAR AND CLUTCH REPLACEMENT
(1) Remove solenoid assembly (Fig. 18).
(2) Remove the two through-bolts securing the
starter drive end housing to the motor housing (Fig.
19) and separate housings. (3) Remove rubber seal (Fig. 20). (4) Pull the gear and clutch assembly from the
drive end housing (Fig. 21). (5) For installation, reverse above procedures.
STARTER INTERLOCK SWITCH: CLUTCH PEDAL
MOUNTED/MANUAL TRANSMISSION ONLY
For electrical diagnostics, refer to Group 8A, Bat-
tery/Starting/Charging Systems Diagnostics, Starter
relays.
Fig. 13 Gear and Clutch Assembly
Fig. 14 Field Terminal Nut
Fig. 15 Field Coil Terminal
Fig. 16 Field Terminal Washer
Fig. 17 Solenoid Mounting Screws
Fig. 18 Solenoid
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 7

For replacement and adjustment of this switch, re-
fer to Group 6, Manual Transaxle Clutch, Manual
Transaxle Starter Interlock Switch.
NEUTRAL STARTER AND BACK-UP SWITCH
For electrical diagnostics when checking the
starter circuits, refer to Group 8A, Battery/Starting/
Charging Systems Diagnostics, Starter Relays. For removal and installation of neutral switch, re-
fer to Group 21, Transaxle Neutral Starter and
Back-up Switch Replacement.
Fig. 19 Through-BoltFig. 20 Rubber Seal
Fig. 21 Starter Drive Gear Train
8B - 8 BATTERY/STARTER/GENERATOR SERVICE Ä

GENERATOR INDEX
page page
General Information ........................ 9
Generator ReplacementÐ2.2L Turbo Engine (With 16 Valve Cylinder Head) ............. 10 Generator ReplacementÐ2.2L/2.5L Engine
...... 9
Generator ReplacementÐ3.0L Engine ......... 10
Generator ReplacementÐ3.3L/3.8L Engine ..... 11
GENERAL INFORMATION
This section will cover generator removal and instal-
lation only. Information covering generator on-vehicle
testing and diagnosis can be found in Group 8A,
Battery/Starting/Charging Systems Diagnostics. To
identify the generator, refer to the Generator Specifi-
cation chart at the rear of this section. These generators are not intended to be disas-
sembled for service. It must be replaced as an
assembly.
GENERATOR REPLACEMENTÐ2.2L/2.5L ENGINE
Removal and repositioning of A/C compressor (with-
out disconnecting refrigerant lines) is necessary on
some models to gain access to generator. (1) Disconnect battery negative cable (Fig. 1).
(2) If Equipped With Air Conditioning:
(a) Remove the A/C drive belt. Refer to Group 7,
Cooling System. (b) Remove the four bolts retaining the A/C com-
pressor to the mounting bracket (Fig. 2). (c) Without disconnecting the A/C refrigerant
lines, position the A/C compressor to allow generator
removal.
WARNING: THE A/C REFRIGERANT SYSTEM IS UN-
DER PRESSURE EVEN WHEN THE ENGINE IS OFF.
REFER TO THE SAFETY PRECAUTIONS AND WARN-
INGS SECTION IN HEATING AND A/C, GROUP 24,
BEFORE PERFORMING ANY SERVICE OPERATION. (3) Remove the generator drive belt. Refer to Group
7, Cooling System. (4) Remove the two generator mounting bolts (Fig.
3) and position the generator to gain access to all the
wire connectors. If equipped with:
² BOSCH GENERATOR: Remove B+ terminal nut,
field terminal nuts, and ground harness hold down
nuts (Fig. 4). Remove wire connector assembly.
² NIPPONDENSO GENERATOR: Remove nuts
from field terminals, ground terminal, wire harness
Fig. 1 Remove Battery Negative (-) Cable
Fig. 2 A/C Compressor ReplacementÐ2.2 L/2.5 L Engine
Fig. 3 Remove/Install Generator
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 9

and B+ terminal (Fig. 5). B+ terminal nut must be
removed last to prevent damage to terminal insula-
tor. (5) Remove the generator from the vehicle.
(6) For installation, reverse above procedures.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.
GENERATOR REPLACEMENTÐ2.2L TURBO
ENGINE (WITH 16 VALVE CYLINDER HEAD)
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Remove generator/air conditioning drive belt.
Refer to Group 7, Cooling System. (3) Remove the bolts retaining the A/C compressor
to the mounting bracket. (4) Without disconnecting the A/C refrigerant
lines, position the A/C compressor to allow generator
removal. WARNING: THE A/C REFRIGERANT SYSTEM IS UN-
DER PRESSURE EVEN WHEN THE ENGINE IS OFF.
REFER TO THE SAFETY PRECAUTIONS AND
WARNINGS SECTION IN HEATING AND A/C,
GROUP 24, BEFORE PERFORMING ANY SERVICE
OPERATION.
(5) Remove the generator mounting bracket bolts
and separate generator from mounting bracket (Fig.
6).
(6) Remove the B+ terminal nut, field terminal
nuts, and ground/wire harness hold-down nuts. Re-
move wire connectors. (7) Remove the generator from the vehicle.
(8) For installation, reverse above procedures.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.
GENERATOR REPLACEMENTÐ3.0L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Remove generator drive belt. Refer to Group 7,
Cooling System. (3) Remove the generator mounting bolts and sep-
arate the generator from the mounting bracket (Fig.
7). (4) Remove the B+ terminal nut, field terminal
nuts, and ground/wire harness hold-down nuts. Re-
move wire connectors. (5) Remove the generator from the vehicle.
Fig. 4 Remove or Install Wire Connector AssemblyÐBosch Generator
Fig. 5 Remove or Install Wire ConnectorAssemblyÐNippondenso Generator
Fig. 6 Generator MountingÐ2.2 L Turbo Engine With 16 Valve Cylinder Head
8B - 10 BATTERY/STARTER/GENERATOR SERVICE Ä

(6) For installation, reverse above procedure.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.
GENERATOR REPLACEMENTÐ3.3L/3.8L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Remove generator drive belt. Refer to Group 7,
Cooling System. (3) Loosen, but do not remove the nut on the sup-
port bracket at exhaust manifold (Fig. 8). (4) Remove the generator tensioner power steering
bracket bolt. (5) Remove the tensioner stud nut and the ten-
sioner (Fig. 9). (6) Remove the generator mounting bolts (Fig. 9).
(7) Remove the power steering reservoir from the
generator mounting bracket. (8) Remove the three generator support bracket
bolts (Fig. 8). (9) Remove intake plenum to generator mounting
bracket bolt. (10) Remove generator support bracket (Fig. 9).
(11) Position the generator to gain access to wiring
and remove wiring from generator. (12) Remove generator.
(13) For installation, reverse above procedures.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.
Fig. 7 Remove or Install Generator Mounting BoltsÐ3.0L Engine
Fig. 8 Support BracketFig. 9 Generator/Generator Support BracketÐ3.3L/ 3.8L Engine
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 11

SPECIFICATIONS
STARTER/BATTERY
GENERATOR AMPERAGE/IDENTIFICATION NUMBERS
8B - 12 BATTERY/STARTER/GENERATOR SERVICE Ä

TORQUE SPECIFICATIONS
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 13