1988 PONTIAC FIERO Service Repair Manual

6D1-6 BATTERY
1 -BATTERY
2-CABLE ASM- POS.
3-CABLE ASM- NEG.
TO PREVENT DIODE DAMAGE, ALL CONNECTIONS
MUST BE MADE AND TIGHTENED BEFORE BATTERY
POSITIVE CONNECTION IS MADE TO BATTERY.
Fig.
60 1 Battery Cables (LB8)

BATTERY 801-7
1 -BATTERY
2-CABLE ASM- NEG.
3-CABLE ASM- POS.
TO PREVENT DIODE DAMAGE, ALL CONNECTIONS MUST BE
MADE AND TIGHTENED BEFORE
BATTERY
POSlTVE CONNEC-
TION IS MADE.
Fig.
602 Battery Cables (LBS/LG4)
SPECIFICATIONS
ENGINE BATTERY/FUNCTION REPLACEMENT
LB8lL03 198 1730-STD 730
CCA 525
RC(MIN)90
~oad ~est 260 Amps
1981731-HD
CCA 570
RC(MIN)90
Load Test 280 AMPS
198 1W-STD
CCA 525
RC(MIN)75
Load Test 260 Amps
1981731-HD
CCA 570
RC(MIWW
Load Test 280 AMPS
1981601
CCA 630
RC(MIN)90
Load Test 310 AMPS

CRANKING SYSTEM CD2-1
CRANK NG SYSTEM
General Description ................................. 6D2-1 Service Procedures .................................. 6D2-3
Cranking System ......................... ... ........ 6D2- 1 Cranking
System ..................... .. ............. 6D2-3
Starter Motor ............................................. 6D2-1 On-Car Service ....................................... 6D2-4 Solenoid .................................................. 6D2- 1
Starter ........................... ... ...................... 6D2-4 Diagnosis ..................................................... 6D2-1 Specifications ............................................. 6D2- I I Cranking System ......................... ... ...... 6D2- 1
Unit Repair ............................................ 6D2-6- 1 1
GENERAL DESCRIPTION
The engine electrical system includes the battery, Battery: To determine the condition of the
ignition (primary and secondary), starter (and related battery,
follow the testing procedure outlined in the
wiring) and the generator (and related wiring). Battery section
(6D1).
Diagnostic charts (see Section 6D) will aid in Wiring: Inspect the wiring for damage. Inspect trouble-shooting system faults. When a fault is traced all connections to the cranking motor, solenoid, to a articular component, refer to that components' ignition switch and battery, including all ground
section of the service manual.
connections. Clean and tighten all connections, as
CRANKING SYSTEM
The cranking circuit consists of the battery,
starting motor, ignition switch, and related electrical
wiring. These components are connected electrically as
shown in Fig. 1.
Starter Motor
Wound field starter motors have pole pieces,
arranged around the armature, that are energized by
wound field coils.
Solenoid
Enclosed shift lever cranking motors have the
shift lever mechanism and the solenoid plunger
enclosed in the drive housing, protecting them from
exposure to dirt, icing conditions and splash.
In the basic circuit shown in Fig. 1, solenoid
windings are energized when the switch is closed. The
resulting plunger and shift lever movement causes the
pinion to engage the engine flywheel ring gear and the
solenoid main contacts to close, and cranking takes
place. When the engine starts, pinion overrun protects
the armature from excessive speed until the switch is
opened, at which time the return spring causes the
pinion to disengage. To prevent excessive overrun, the
switch should open immediately when the engine
starts.
DIAGNOSIS
CRANKING SYSTEM
Before removing any unit in a cranking circuit for
repair, the following checks should be made:
Electrical System General Diagnosis:
Follow the procedures shown in Section 6D to isolate
problem. required.
Solenoid
and Ignition Switch: Inspect all
switches to determine their condition.
Starter Motor Noise: To correct starter motor
noise during starting, use the following procedure:
1. Refer to Fig. 2 to determine the problem.
2. If the complaint is noise, correction can be
achieved by proper "shimming" as follows:
a. Check
flywheel for damage
- bent flywheel,
unusual wear, etc.
b. Start
engine and carefully touch outside
diameter of rotating flywheel ring gear with
chalk or crayon to show high point of tooth
runout. Turn engine off and rotate flywheel
so that the marked teeth are in the area of
the starter pinion gear.
c. Disconnect negative battery cable to
prevent cranking of engine.
d. Check pinion to flywheel clearance, as
shown in Fig. 3, by using a wire gage of
.5mm (.02OU) minimum thickness (or
diameter). Center a pinion tooth between
two flywheel teeth and gage, as shown in
Fig. 3. Do not gage in the corners, where a
misleading larger dimension may be
observed. If the clearance is under this
minimum, shimming the starter away from
the flywheel is required.
e. If
the clearance is grossly over
.5mm (.02OU)
in the vicinity of 1.5mm (.06OU) or more,
shimming the starter toward the flywheel is
required. (This is generally the problem
causing broken flywheel teeth or starter
housings.) Shimming the starter toward the
flywheel can be accomplished by shimming
only the outboard starter mounting pad.
A
shim of .4mm (.015") thickness, at this

6D2-2 CRANKING SYSTEM
1-SWIFT LEVER m
SPRING 17-FLYWHEEL I
I G20198-6D
Fig. 1 Cranking Circuit - 5MT or PMGR
PROBLEM CAUSE - 1. HIGH PITCHED WHINE DURING CRANKING (BEFORE DISTANCE
TOO GREAT BETWEEN STARTER PINION AND
ENGINE FIRES) BUT ENGINE CRANKS AND FIRES FLYWHEEL.
OKAY - 2. HlGH PITCHED "WHINE"
AFTER ENGINE FIRES, AS
KEY IS BEING RELEASED. ENGINE CRANKS AND
FIRES OKAY. THlS INTERMITTENT COMPLAINT IS
OFTEN DIAGNOSED AS "STARTER HANG-IN"
OR "SOLENOID WEAK."
3. A LOUD "WHOOP" AFTER THE ENGINE FIRES BUT
WHILE THE STARTER IS STILL HELD ENGAGED.
SOUNDS
LIKE A SIREN IF THE ENGINE IS REVVED
WHILE STARTER IS ENGAGED.
4. A "RUMBLE. "GROWL" OR (IN SEVERE CASES) A
"KNOCK" AS THE STARTER IS COASTING DOWN TO
A STOP AFTER STARTING THE ENGINE. DISTANCE
TOO
SMALL BETWEEN STARTER PINION AND
FLYWHEEL. FLYWHEEL RUNOUT CONTRIBUTES TO THE
INTERMITTENT NATURE.
MOST PROBABLE CAUSE IS A DEFECTIVE CLUTCH. A NEW
CLUTCH
WlLL OFTEN CORRECT THlS PROBLEM.
MOST PROBABLE CAUSE IS A BENT OR UNBALANCED
STARTER ARMATURE. A NEW ARMATURE
WlLL OFTEN
CORRECT THlS PROBLEM.
620026.60
Fig. 2 Starter Motor Noise Diagnosis
location will decrease the clearance by is known to be functioning properly, remove the motor
approximately
.3mm (.01OU). and follow the procedures shown in Starter Motor
Disassembly, Test and Reassembly (Unit Repair).
If normal starter shims are not available, they can
Never operate the cranking motor more than 30
be improvised from plain washers or other suitable
seconds at a time without pausing to allow it to cool material.
for at least two minutes. Overheating, caused by
excessive cranking, will seriously
damage the cranking Starter Motor: If the battery, wiring and motor, switches are in satisfactory condition, and the engine

CRANKING SYSTEM 882-3
.5mm (.02OU)
WIRE GAUGE
I
Fig. 3 Flywheel to Pinion Clearance
SERVICE PROCEDURES
CRANKING SYSTEM 5MT and 10 MT Starters
1. The roll type overrunning clutch requires no
lubrication; however, the drive assembly should
Starting motors do not require lubrication except be wiped clean.
Do Not clean in
any deereasing
during overhaul. tank, or
with grease dissolving solvents; this will
dissolve the lubricant in the clutch mechanism.
Use silicon grease General Electric
CG321, Dow
When the motor is disassembled for any reason, Corning
33 Medium, or equivalent, on the shaft
lubricate as follows: underneath
the overrunning clutch assembly.
2. Avoid excessive lubrication.
1 -CONTACT DISC 2-PLUNGER
3-SOLENOID
4-RETURN SPRING
5-SHIFT LEVER
6-BUSH ING
7-PINION STOP
8-CLUTCH
9-FIELD
COIL
10-ARMATURE
11-BRUSH
12-TERMINALS
Fig.
4

(iD2.4 CRANKING SYSTEM
1-FRAME-COMMUTATOR END
2-BRUSH AND HOLDER PKG.
3-BRUSH
4BRUSH HOLDER
5-HOUSING-DRIVE END
6-FRAME AND FIELD ASM.
7-SOLENOID SWITCH
8-ARMATURE
9-DRIVE ASM. 10-PLUNGER
1 1-SHIFT
LEVER
12-PLUNGER RETURN SPRINGER
13-SHIFT LEVER SHAFT
14-LOCK WASHER
15-SCREW-BRUSH ATTACHING
16-SCREW-FIELD LEAD TO SWITCH
17-SCREW-SWITCH ATTACHING
18-WASHER-BRAKE 19-THRU
BOLT
20- BUSHI NG-COMMUTATOR END
21- BUSHING-DRIVE END
22- PINION STOP COLLAR
23-THRUST COLLAR
24-GROMMET
25-GROMMET
26-PLUNGER PIN
27-PINION STOP RETAINER
RING
28-LEVER SHAFT RETAINING RING
Fig. 4A 5MT Starting Motor - Disassembled View
ON-CAR
H20248-6D
Fig. 601 Starter Motor Mounting VIN F, H, 8
Starting motors do not require lubrication except
during overhaul. When the motor is disassembled for
any reason, lubricate as follows:
1. The roll-type overrunning clutch requires no
lubrication. However, the drive assembly should
be wiped clean. DO NOT clean in any degreasing
tank or with grease dissolving solvents; this will
dissolve the lubricant in the clutch mechanism.
Use silicone grease General Electric
CG32 1, Dow
SERVICE
. - . . . - - . REMOVE 1 - ,015" DOUBLE SHIM OR ADD
SINGLE
.015" SHIM TO OUTER BOLT ONLY.
2. HIGH PITCHED WHINE AFTER ENGINE
FIRES: ADD
.015" DOUBLE SHIMS UNTIL
NOISE DISAPPEARS.
SEE TEXT FOR COMPLETE PROCEDURE.
Fig. 602 Starter Motor Shims

CRANKING SYSTEM 882-5
Corning 33 Medium or equivalent, on the shaft
underneath the overrunning clutch assembly.
2. Avoid excessive lubrication.
STARTER
Use the following procedure to remove the
starter:
1. Disconnect negative battery lead at battery.
2. Raise car.
3. Remove starter braces, shields, etc., that may be
in the way.
4. Remove two starter motor to engine bolts, and
allow starter to drop down.
5. Remove solenoid wires and battery cable and
remove starter.
6. To replace, reverse the above procedure. Ensure
that any shims removed are replaced.
SOLENOID
Use the following procedure to remove the
solenoid from the starter:
1. Disconnect field strap.
2. Remove solenoid to drive housing attaching
screws, motor terminal bolt, and remove solenoid
by twisting.
3. Replace by reversing above procedures.
OVERRUNNING CLUTCH
1. Test overrunning clutch action. The pinion
should turn freely in the overrunning direction.
Check pinion teeth to see that they have not been
chipped, cracked or excessively worn. Replace
assembly if necessary. Badly chipped pinion teeth
may indicate chipped teeth on the ring gear. This
should be checked under such conditions and
replaced if necessary.
2. Check the overrunning clutch for slipping by
leaving the clutch attached to the armature.
Wrap the armature with a shop towel and clamp
the armature in a vise. Using a 12-point deep
socket and torque wrench, put the socket on the
clutch and turn counterclockwise. The clutch
should not slip up to
68 N-m (50 ft. lb.) of torque.
If it does, replace the clutch.
h LB8 ENGINE
a STARTER MOTOR
BOLT
FRT
BRACKET NUT
WASHER
Fig. 602A--Starter Motor Mounting