Assembly Procedure

1. Install the following to terminal 30:
1.1. The insulation paper (6)
1.2. The inside insulator (8); long side (7), short side (9)
1.3. The contact plate (10)
1.4. The terminal bolt (11)
1.5. The O-ring (5)
1.6. The packing and outside insulator (4)
1.7. The wave washer (2)
1.8. The nut (1)
2. Do not tighten the nut (1) at this time.




3. Install the following to terminal C:
3.1. The inside insulator (3); long side (4), short side (5)
3.2. The contact plate (2)
3.3. The terminal bolt (1)
3.4. The O-ring (6)
3.5. The outside insulator (7)
3.6. The wave washer (8)
3.7. The terminal nut (9)
4. Do not tighten the nut (9) at this time.





IMPORTANT: If the contact plate is not pressed down evenly, the contact plate may tilt due to the tightening of the nut. If the nut is over tightened, it may cause cracks on the inside of the insulator.

NOTE: Refer to Fastener Notice in Cautions and Notices.

5. Place a wooden block on the contact plates and press it down with a hand press. Use only enough force to hold the contact plates firmly seated in the solenoid assembly. Tighten the nuts.

Dimensions of the wooden block are 20x37x40 mm (.79x1 .46x1 .57 in).

Tighten
Tighten the nuts to 17 N.m (12 lb ft).




6. Clean the contact surfaces of the contact plates (2) and the plunger (1) with a clean dry cloth.
7. Install the solenoid plunger.
8. Install the solenoid end cover.

Tighten
Tighten the nuts to 2.5 N.m (23 lb in).

9. Apply a light coating of Lubriplate lubricant GM P/N 1050109, or an equivalent, to the following locations:
^ The front armature bearing
^ The rear armature bearing
^ The idler gear roller bearing




10. Install the armature into the field frame.
11. Install the brush holder.
12. Connect the four brushes.
13. Hold the spring back with a small screwdriver (2) and install the brush (4) into the brush holder.




14. Install the end cover (2) to the field frame. Install a new O-ring
^ Install the two screws (3)

Tighten
Tighten the screws to 1.5 N.m (13 lb in).




15. Install the steel ball (2) to the clutch and drive assembly.




16. Install the following to the drive housing:
^ The idler gear roller bearing (1)
^ The idler gear (5)
^ The clutch and drive assembly (4)
^ The return spring (3)




17. Install the drive housing (1) to the solenoid assembly

Tighten
Tighten the two bolts to 6 N.m (52 lb in)




18. Install the field frame to the solenoid assembly using a new O-ring.

Tighten
Tighten the two through bolts (1) to 6 N.m (52 lb in).




19. Install the solenoid lead wire and nut (1) to the solenoid assembly.

Tighten
Tighten the nut (1) to 6 N.m (52 lb in).

20. Install the starter motor to the vehicle.