You can correct irregular starter noise with shims. If diagnosis leads to starter shimming, use the following pinion clearance procedure.

1. Remove the flywheel housing cover.
2. Inspect the flywheel for signs of unusual wear such as chipped or missing gear teeth or the flywheel being bent. If the flywheel needs replacing, refer to Engine Flywheel Replacement in Engine Mechanical.
3. Start the engine and gently touch the outside diameter of the rotating flywheel ring gear with chalk or crayon in order to show the high point of tooth runout after the engine turns off. Turn the engine off and rotate the flywheel so that the marked teeth are in the area of the starter pinion gear.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

4. Disconnect the negative battery cable.



5. Measure the clearance between the top of the ring gear tooth and the bottom of the pinion tooth. Use the width of a wire gauge. Normal clearance is 0.5-1.5 mm (0.02-0.06 in).



6. If the clearance is less than 0.5 mm (0.02 in) and the starter whines after firing, shim the starter away from the flywheel.
7. Add 1.0 mm (0.04 in) shims, one at a time, to both long bolts between the starter mounting pads and engine until the noise problem is corrected. Do not use more than 2 shims total.
8. If the pinion clearance is more than 1.5 mm (0.06 in) and the starter whines during cranking, shim the starter toward the flywheel.
9. Add 0.33 mm (0.013 in) shims between the outboard starter mounting pad and the engine mount until the noise stops. Do not add more than 4 shims total.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

10. After shimming, tighten the mounting bolts.

Tighten
Tighten the starter mounting bolts to 40 N·m (30 lb ft).

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

11. Connect the negative battery cable.