Car (91 mitsu Galant) makes grinding noise when I try to start, after new bolts were installed, started right up then 2 days later, it began grinding again but starts right up if someone holds the starter and engine together. Is there a way to fix this without replacing the starter?
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First, make sure that both battery terminals (on battery) are clean, AND tight. Your electronics can function without having enough juice to turn the motor over...If not the posts...sounds like the starter has worn out..
Find a strip of white pasteboard (like the form used in the collar of a new shirt. Cut it in the shape of the chip key from the handle to the beginning of the key pin cuts (don't make it any longer than this; you don't want to grind pasteboard into the lock mechanism). Slide it into the lock several times to clean off any gunk that might have been deposited on the chip contacts. Clean both sides of the chip on the key with a paper towel or cotton swab dampened with rubbing alcohol, then dry it. If it still doesn't work, you may have bent the contacts in the lock, and it needs to be taken apart for repair.
Sometimes the starter needs a shim installed to help this problem. If there was not a grinding noise with old starter you should be able to install a shim,these shims you can get at your auto parts store. they come in several thicknesses, most times you get 2 or 3 different thicknesses in a pack. Start with the thinner one and loosen the two starter bolts 3 to 4 turns then remove bolt furthest from engine , shim will slide in and slot at end should stradle bolt, align hole at other end and install other bolt and retighten bolts. test starter for noise,if noise is gone your done, if not try next thicker shim till noise is gone sometimes damage to the teeth on the flywheel can cause this noise but try the shims first. Good Luck!
It could be a loose battery cable to starter connection or loose ground wire or corrosion on the battery cables or wires. I would check all connections and wires for looseness, wear and corrosion and tighten or replace as needed,
have you reset the ecu? disconnect the battery for 5 minutes. make sure you have any radio codes if your radio has a security code lock.
Also could be the idle control stepper. Mitsu gives it some name like ICU but it's a small mottor attached to the throttle that opens and closes valves to let a little more air in and up the rpm.if it's sticky try cleaning the throttle and the valves.
try using some thread locker on the bolts. If this still doesn't help, you may have to get a helicoil repair kit. These kits repair damaged threads by drilling the bad ones out, tapping the hole with new threads, then screwing a thread adapter in to bring it back to the original size.
Hope this helps:)
If you are Getting a Grinding noise, It is going to be the Starter. I would get the Fuel Pump and Filter Checked out also as the Starter would not cause the Car to Die. But, The Fuel Pump and Filter Would. Let me know what you find!