J Car - Cavalier/Sunfire With 2.3L or 2.4L (VIN Code D or T)
IMPORTANT:If the vehicle is a 1995 model with a 2.3L engine and equipped with the original starter solenoid, it will be necessary to enlarge the hole in the large ring terminal on the harness kit prior to installing the harness on the vehicle. Enlarging the terminal hole diameter is required in order for it to fit on the larger diameter battery terminal stud used on the original starter solenoids. If the starter solenoid is not the original, enlarging the hole in the terminal may not be necessary.
NOTICE:
When performing the enlarging procedure, make sure the ring terminal is carefully secured in a vice to prevent movement/rotation while enlarging the eyelet.
^ Carefully secure the large ring terminal from the service kit wiring harness (blue, blue/grey, or green fuse link attached to the red wire) in a vice. Using a 10.0 mm (13/32 inch) drill bit, slowly and carefully enlarge the hole in the eyelet to an inside diameter to 10.0 mm (13/32 inch). Remove the enlarged ring terminal from the vice.
1. Remove the two 10 mm hex head bolts that secure the air cleaner outlet resonator to the throttle body.
2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct.
3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing.
4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body.
5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body.
6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4).
7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 inch) to be drilled.
8. Remove the J-nut and using a 6.35 mm (1/4 inch) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled.
9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material.
10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 inch) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
11. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole.
13. Using the 10 mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut. Tighten the bolt to 10 N.m (89 A lb.in.).
IMPORTANT:
The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harnesses together in the next step.
14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness.
15. Remove the top starter bolt.
16. Raise the vehicle on a suitable hoist.
17. Remove the oil filter.
18. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove the brace.
19. Remove the bottom starter bolt and remove the starter.
20. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
21. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid.
^ If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to step 29 and remove the nut. Do NOT perform steps 22-28 if the stud and nut are in good condition.
^ If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to step 22 of this procedure. Steps 22-24 will require the use of one ADDITIONAL butt connector P/N 12089191. Obtain the additional butt connector before proceeding.
22. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 inches) of wire on the terminal.
23. Strip the insulation back about 1/4 inch (6.35mm) on the short purple wire that remained on the starter solenoid.
24. Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire.
25. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
26. Strip the insulation back about 1/4 inch (6.35 mm) on the red wire.
27. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire.
28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
IMPORTANT:
If you have just completed steps 22-28, proceed to step 31. Do NOT perform steps 29-30. If you did NOT perform steps 22-28, proceed to step 29.
29. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal.
30. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
31. Strip the insulation back about 1/4 inch (6.35 mm) on the purple wires of the vehicle wiring harness and the service harness kit.
32. Using an appropriate crimping tool install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly.
33. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
IMPORTANT:
If you performed steps 22-28 earlier, proceed to the next "IMPORTANT" statement prior to step 36. Do not perform steps 34-35. If you did NOT perform steps 22-28 earlier, proceed to step 34.
34. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
35. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut and tighten to 2.5 N.m (22 lb.in.).
IMPORTANT:
In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.
36. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
37. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
38. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
39. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut and tighten to 11 N.m (8 lb.ft.).
40. If equipped, remove the 10 mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts that attach the starter solenoid to the starter motor. See illustration for solenoid bolt location.
41. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud and tighten to 18 N.m (13 lb.ft.). If installed on the starter solenoid, install the bolt and tighten to 9 N.m (79 lb.in.).
42. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time.
43. Lower the vehicle.
44. Install the upper starter bolt and tighten to 90 N.m (66 lb.ft.).
45. Raise the vehicle.
46. Tighten the lower starter bolt to 90 N.m (66 lb.ft.).
47. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold and tighten to 24 N.m (18 lb.ft.) Tighten the two bolts to the engine block to 26 N.m (19 lb.ft.).
48. Install a new oil filter.
49. Lower the vehicle.
50. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator.
51. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator.
52. Install the air cleaner outlet resonator on the throttle body and tighten the clamp to 5 N.m (44 lb.in.).
53. Connect the air cleaner outlet duct to the air cleaner housing and tighten the clamp to 5 N.m (44 lb.in.).
54. Connect the electrical connector to the sensor in the air cleaner outlet duct.
55. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator. Tighten to 10 N.m (88 lb.in.).
56. Reinstall the negative battery cable to the battery. Tighten the bolt to 16 N.m (12 lb.ft.).
IMPORTANT:
Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.
57. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.
^ If the starter cranks the engine 6 times in a row, proceed to the next step.
^ If the starter will NOT crank the engine, skip to Procedure A for J car Cavalier/Sunfire.
58. Check the engine oil level and add as necessary.
59. Install the GM Recall Identification Label.