Starter Installation

NOTE: Never operate the starter motor for more than 30 seconds at a time. Allow it to cool for at least two minutes. Overheating, caused by too much cranking, will damage the starter motor.

The following procedure is to correct a noise condition. Shims are available to adjust the starter drive pinion-to-flywheel clearance.

1. Remove the flywheel housing cover.
2. Inspect the flywheel for the following signs of unusual wear:
- Chipped gear teeth
- Missing gear teeth
- A warped flywheel

3. Repair or replace as necessary, then retest before continuing with this procedure.
4. Start the engine.
5. Gently touch the outside diameter of the rotating flywheel ring gear with a piece of chalk.
This will show the high point of tooth runout, after the engine is stopped.
6. Turn OFF the engine.
7. Rotate the flywheel so that the marked teeth are in the area of the starter pinion gear.
8. Disconnect the negative battery cable.
9. Measure the clearance between the top of the ring gear tooth and the bottom of the pinion tooth.
- Use the width of the wire gauge.
- Normal clearance is from 0.5-1.5 mm (0.01-0.06 in).
- Starter shims are available in sizes 1.0 mm (0.04 in), and 0.33 mm (0.013 in).




10. The starter must be shimmed away from the flywheel it the following is true:
- The pinion clearance is less than 0.5 mm (0.02 in)
- The starter whines after the engine fires.
- Add 1.0 mm (0.4 in) shims, one at a time.
- Loosen both starter mounting bolts enough to add the shims.
- Place the shims between the starter mounting pads and the engine block.
- Do not use more than two shims total.
- Tighten the bolts to specifications, then retest.

11. The starter must be shimmed toward the flywheel if the following is true:
- The pinion clearance is more than 1.5 mm (0.06 in).
- The starter whines only during cranking.

- Add 0.33 mm (0.013 in) shims between the outboard starter mounting pad and the engine.
- Loosen the inboard bolt.
- Remove the outboard bolt.
- Install the shim.
- Install the outboard bolt.
- Tighten both bolts to specifications, then retest.
- Do not add more than four shims total.

12. Ensure that the starter mounting bolts are tighten to 43 N.m (31 lb. ft.).