1988 PONTIAC FIERO Service Repair Manual

6D2-6 CRANKING SYSTEM - -
5MT AND IOMT STARTER MOTORS
DISASSEMBLY, TEST AND REASSEMBLY
(STARTER REMOVED FROM ENGINE)
With the starter motor removed from the engine, the pinion
should be checked for freedom of operation by turning it on the
screw shaft. The armature should be checked for freedom of
rotation by prying the pinion with a screwdriver.
If the armature
does not turn freely, the motor should be disassembled im-
mediately. However,
if the armature does rotate freely, the
motor should be given
a no-load test before disassembly.
Make connections as shown. Close the switch and compare
the
RPM, current, and voltage readings with the specifications If the specified current draw does not include
the solenoid, deduct from the ammeter reading the specified
current draw of the solenoid hold-in winding. Make disconnec-
tions only with the switch open. Use the test results as follows:
I. Rat4 current draw and no-load speed Indicates normal
condition of the starter motor.
2. Low free spc4 and high current draw indicates:
e Too much friction - tight, dirty, or worn bearings, bent
armature shaft allowing armature to drag.
e Shorted armature. This can be further checked on a
growler after disassembly.
e Grounded armature or fields. Check further after disas-
sembly.
3. Failure to operate with high current draw indicates: e A direct ground in the terminal or fields.
"Frozen" bearings (this should have been determined by
turning the armature by hand).
4. Failure lo operate with no current draw indicates:
Open field circuit. This can be checked after disassembly
by inspecting internal connections and tracing circuit with
a test lamp.
Open armature coils. Inspect the commutator for badly
burned bars after disassembly.
Broken brush springs, worn brushes, high insulation be-
tween the commutator bars or other causes which would pre-
vent good contact between the brushes and commutator.
5. Low no-loed speed and low current draw indicates:
e High internal resistance due to poor connedtions, defec-
tive leads, dirty commutator and causes listed under Number
4.
6. High free speed and high current draw usually Indicate
shorted fields. If shorted fields are suspected, replace the field
coil assembly. Also check for shorted armature, using
a
growler.
Fig. 603 Starter Motor Disassembly, Test and Reassembly 1 of 6

CRANKING SYSTEM 602-7
STARTER DISASSEMBLY
RETURN
SOLENOID
DRIVE
GEAR
END FRAME
l NSU LATO R COMMUTATOR
END FRAME
THRUST
- FIBER FIELD FRAME
CLUTCH AND CENTER ARMATURE
DRIVE ASM. BEARING
7. Remove screw from field coil connector and solenoid 8. Remove 2 through bolt. then remove commutator end
mounting screws. Rotate solenoid
9(P and remove along with frame
(diesel only. remove insulator) and washer.
plunger return spring. Solenoid may now be serviced without 9. Remove field frame assembly from drive gear housing.
further starter disassembly at this time. (On
diesel starter, armature remains in drive end frame.)
qHIFT LEVER
PIVOT BOLT PIN PLUNGER

DRIVE
GEAR
HOUSING
Steps
I0 and I I are required only on diesel starters. 10. Remove shift lever pivot bolt.
1 1. Remove drive gear housing from armature shaft. Shift ver and plunger assembly will now fall away from starter
utch.
FIBER SHAFT M WASHER
CENTER/ CLUTCH A~D DRIVE RING
BEARING ASSEMBLY
12. If necessary to remove overrunning clutch from armature
shaft. proceed as follows:
a. Remove thrust washer or collar from armature shaft.
b. Slide a
5/8* deep socket or piece of pipe of suitable size
over shaft against retainer as a driving tool. Tap tool to move
retainer off snap ring.
c. Remove snap ring from groove in shaft.
If snap ring is
distorted. it will be necessary to use a new one on reassem-
bly.
d. Remove retainer, clutch assembly (also
fiber washer
and center bearing on diesel) from armature shaft.
13. The shift lever and plunger may be disassembled at this
time by removing the roll pin.
Fig. 604 Starter Motor Disassembly, Test and Reassembly 2 of 6

682-8 CRANKING SYSTEM
REPLACE BRUSH HOLDER
(SMALL 5MT STARTER)
INTEGRAL ROUTE
WIRE
14. If necessary to replace brush holder pans, proceed as fol- (
CLEANING INSPECTION
AND ""FSTS
GHT damage or wear. Replace as required. 17. Check fit of armature shaft in bushing in drive housing.
Shaft should fit snugly in the bushing. If the bushing is worn, it
should be replaced.
18. Inspect armature commutator. If commutator is rough, it
should be turned down. Do not undercut or turn to less than
1.65U' O.D. Do not turn out-of-round commutators, Inspect the
points where the armature conductors join the commutator bars
to make sure they have a good connection.
A burned com-
mutator bar is usually evidence of a poor connection.
19. If test equipment is available:
a. Check the armature for short circuits by placing on
growler and holding hack saw blade over armature core
while armature is rotated. If saw blade vibrates, armature is
shorted. Recheck after cleaning between the commutator
bars. If saw blade still vibrates. replace the armature.
b. Using a test lamp. place one lead on the shunt coil ter-
minal and connect the other lead to a ground brush. This test
should
be made from both ground brushes to insure con-
Fig. 605 Starter Motor Disassembly, Test and Reassembly 3 of 6

CRANKING SYSTEM BD2-9
I TESTING SERIES COIL FOR OPEN I
TESTING SOLENOID WINDINGS
c. Us~ng a test lamp. place onelead on the series coil ter-
minal and the other lead on the insulated brush. If the lamp
fails to light. the series coil is open and will require repair or
replacement. This test should be made from each insulated
brush to check brush and lead continuity.
TESTING SERIES COlL FOR GROUND
THESE TWO TERMINALS
MUST BE SEPARATED
d. On starters
withshunt coil. sepanate series and shunt
coil strap terminals during this test. Do not let strap terminals
touch case or other ground. Using a test lamp place one lead
on
he grounded brush holder and the other lead on either
insulated brush. If the lamp lights, a grounded series coil is
indicated and must be repaired or replaced. VOLTMETER
e. Check the current draw of the solenoid winding as fol-
lows:
If solenoid is not removed from starting motor. the connec-
tor
strap terminals must be removed from the terminal on the
solenoid before making these tests. Complete tests in a
minimum of time to prevent overheating of the solenoid.
To check hold-in winding, connect an ammeter in series
with 12-volt battery and the "switch" terminal on the solenoid.
Connect a voltmeter to the "switch" terminal and to ground.
Connect carbon pile across battery. Adjust the voltage to
10 volts and note the ammeter reading. It should be 13 to 19 amperes for all starting motors.
To check both windings. connect as for previous test.
Ground the solenoid motor terminal. Adjust the voltage to 10
volts and note the ammeter reading. It should be
59 to 79 am-
peres for all starting motors.
NOTE: Current will decrease as windings heat up.
Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid and the
solenoid should be replaced. Current draw readings that are
under specifications indicate excessive resistance. No reading
indicates an open circuit. Check connections then replace sole-
noid if necessary.
H20255.6D
Fig. 606 Starter Motor Disassembly, Test and Reassembly 4 of 6

6D2-10 CRANKING SYSTEM
SOLENOID SWITCH DISASSEMBLY
I
COVER
3
f. The starter solenoid switch is servlced as an assembly.
The cover can be removed to Inspect the contacts and contact dlsc rf necessary.
STARTER ASSEMBLY
INSTALLING RETAINER, WASHER AND RING
1 THRUST WASHER
I 20. Assemble the armature and clutch as follows:
a. Lubricate dnve end of armature shaft w~th lubricant
1960954 or equ~valent. b. Install center bearrng (dresel starters) wrth bear~ng to-
ward the armature w~nd~ng. Then install the fiber washer on
the armature shaft
c Slide clutch assembly onto armature shaft
w~th plnlon dwdy from armature.
d. Sllde retainer onto shaft w~th cupped 51de facing the end
of shaft.
e
Install snap rrng Into groove on armature >haft. f. Install thrust washer on bhaft.
g I'os~t~on retmer ~nd thrust washer with snap rlng in be-
tween Usrng two pl~ers, gnp retalner ~nd thrust washer or sollar and bqueeze unt~l snap rrng 15 forced Into retainer and 15 held becurely In groove rn ,
mature shaft. 26 Po5111on field frame agarnst drrve gear houb~ng on alrgn 21. Lubr~cate dr~ve gear housrng bush~ng w~th lubricant ment pln uslng care to prevent damage to brushes.
1960954 or equtvalent. 27 Lubrrcate commutator end-frame bush~ng wrth lubncan~ 22. Engage shift lever yoke w~th clutch and jlrde complete 1960954 or equ~vnlent assembly Into dnve gear houb~ng. 28 Install washer on armature >haft and sl~de end frame onto
On non-diesel starters the sh~ft lever may be ~nslalled In \haft, then ~nstall and t~ghten through-bolts. On d~esel starter
drrve gear houslng first. ~nstall ~nsulator and then end frame onto shaft. Then ~nstall
23. Install the shift lever p~vot bolt. Tighten secure. through bolts. maklng jure they pass through bolt holes In In-
IY. sulator
24 Install solenold assembly. 29 Connect the tirld co11 connector to the solenold term~nal 25. Apply \ealrr. No. 1050026 or equ~valent to bolenold 30. Check plnron clearance ,I> outi~ned under PlNlOh flange where field frame contacts 11. CLEARANCE.
520046.6D
Fig. 607 Starter Motor Disassembly, Test and Reassembly 5 of 6

CRANKING SYSTEM BD2-11
CHECKING PINION CLEARANCE When the starter motor has been disassembled or the sole-
PRESS ON CLUTCH TO noid has been replaced, it is necessary to check the pinion
clearance. Pinion clearance must be correct to prevent the but-
tons on the shift lever yoke from rubbing on the clutch collar
during cranking.
3 1. Disconnect the motor field coil connector from the sole-
noid motor terminal and insulate it carefully.
32. Connect one 12 volt battery lead to the solenoid switch
terminal and the other to the starter frame.
33. Flash a jumper lead momentarily from the solenoid motor
FEEL^^ terminal to the starter frame. This will shift the pinion into
cranking position and it will remain so until the battery is dis-
connected.
34. Push the pinion back as far as possible to take up any
movement. and check the clearance with a feeler gage. The
clearance should be
.01OV to .140.
Means for adjusting pinion clearance is not provided on the
starter motor. If the clearance does not fall within limits, check
for improper installation and replace all worn parts.
520047-6D
Fig. 608 Starter Motor Disassembly, Test and Reassembly 6 of 6
Engine (RPO/VIN) 2.8L-V6-LB8-%
Starter 5MT-1998524
-No Load Test
@ 10V Min. 50A Max. 75A
6000 rprn
- 1 1,900 rpm
Solenoid
-Hold-in Windings
13- 19A
@ IOV
----Pull-in Windings 23-30A
@ 5v
Engine (RPO/VIN) 5.OL-V8-L03-E
Starter IOMT-1998580
(Auto Trans)
No Load Test
@ 10V Min. 70A Max. 1 lOA
6500 rpm - 10,700 rprn
Solenoid
-Hold-in Windings
13- 19A
@ 1ov
-Pull-in Windings 23-30A
@ 5v
5 .OL-V8-LB9-F
IOMT- 1998580
(Auto Trans)
Min. 70A Max.
1 lOA
6500 rpm - 10,700 rprn
5
.OL-V8-L03-E
5MT- I998527
(Manual Trans)
Min. 52A Max. 76A
6000 rprn
- 12,000 rprn
5.OL-V8-LB9-F
5MT-1998527
(Manual Trans)
Min. 52A Max. 76A
6000 rprn
- 12,000 rprn
Min. 70A Max.
1 lOA
6500 rpm - 10,700 rpm

CHARGING SYSTEM 6D3-1
SECTION 6D3
CHARG NG SYSTEM
CONTENTS
General Description ................................. 6D3- 1 Charging System ........................................ 6D3- 1
.......................................... Charging System - CS ............................... 6D3- 1 On-Car Service 6D3-2
................................................... Diagnosis .. 6D3- 1 Generator 6D3-3 ...................... ......................... ............................................. 6D3- 1 Specifications 6D3-3 Service Procedures .................................. Unit Repair .. 6D3-4-6 ............................... ............
GENERAL DESCRIPTION
The engine electrical system includes the battery,
ignition (primary and secondary), starter (and related
wiring) and the generator (and related wiring).
Diagnostic charts (see Section 6D) will aid in
trouble-shooting system faults. When a fault is traced
to a particular component, refer to that components'
section of the service manual.
CHARGING SYSTEM-CS
The CS Charging System has several sizes
available, including the CS-130 and CS-144. The
number (130 or 144) denotes the
OD in mm of the
stator laminations.
CS generators use a new type regulator and a
diode trio is not used. A delta stator, rectifier bridge,
and rotor with slip rings and brushes are electrically
similar to earlier generators. A conventional pulley and
fan is used and, on the CS-130, an internal fan cools the
slip ring end frame, rectifier bridge and regulator.
Unlike three-wire generators, the CS-130 and
CS-144 may be used with only two connections
-
battery positive and an "L" terminal to the charge
indicator bulb. Use of "P",
"F", and "S" terminals is
optional. The "P" terminal is connected to the stator,
and may be connected externally to
a tachometer or other
device. The
"F" terminal is connected internally
to field positive, and may be used as a fault indicator.
The "S" terminal may be connected externally to a
voltage, such as battery voltage, to sense voltage to be
controlled.
As on other charging systems, the charge
indicator lights when the switch is closed, and goes out
when the engine is running. If the charge indicator is
on with the engine running, a charging system defect
is indicated. For all kinds of defects, the indicator will
glow at full brilliance, not "half lit". Also, the charge
indicator will be on with the engine running if system
voltage is too high or too low. The regulator voltage
setting varies with temperature, and limits system
voltage by controlling rotor field current.
This regulator switches rotor field current on and
off at a fixed frequency of about 400 cycles per second.
By varying the on-off time, correct average field
current for proper system voltage control is obtained.
At high speeds, the on-time may be 10% and the
off-time 90%. At low speeds, with high electrical loads,
on-off time may be 90% and
lo%, respectively.
No periodic maintenance on the generator is
required.
DIAGNOSIS
SERVICE PROCEDURES
CHARGING SYSTEM
The generator does not require periodic
lubrication. The rotor shaft is mounted on ball bearings
at the drive end and roller bearings at the slip ring end.
Each contains a permanent grease supply. At periodic
intervals, check mounting bolts for tightness and adjust
belt tension (see Section
6B), if applicable.
e When adjusting belt tension, apply pressure at
center of generator, never against either end
frame.
GENERATOR BENCH CHECK-CS
To check generator in a test stand, remove as
specified in On-Car Service and proceed as follows: 1.
Make connections as shown in Figure
lH, except
leave the carbon pile disconnected. The ground
polarity of generator and battery must be the
same. The battery must be fully charged. Use a
30-500
OHM resistor between battery and "L"
terminal.
2. Slowly increase generator speed and observe
voltage.
3. If the voltage is uncontrolled and increases above
16.0 volts, the rotor field is shorted, the regulator
is defective, or both.
A shorted rotor field coil can
cause the regulator to become defective. NOTE:
The battery must be fully charged when making
this test.