1998-2001 J-Car - Cavalier/Sunfire With 2.2L (VIN Code 4)
1998-2001 J-Car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4)
1. 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). If there is no clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut.
2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled.
3. Remove the J-nut and using a 6.35 mm (1/4 in) 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.
4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material.
5. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
6. Using an appropriate crimping tool, install one end of the butt connector, included in the harness kit, on the purple wire.
7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole.
8. 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
Tighten the bolt to 10 Nm (89 lb in).
Important:
The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harness together in the next step.
9. 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.
10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
11. 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 19 and remove the nut. Do NOT perform Steps 12-18 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 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.
12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (1/4 in) of wire on the terminal.
13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire.
15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
17. 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.
18. 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 12-18, proceed to Step21. DO NOT perform Steps 19-20. If you did NOT perform Steps 12-18, proceed to Step 19.
19. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal.
20. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal.
21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit.
22. 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.
23. 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 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24.
24. Thoroughly clean the interface surfaces of the "S" terminal. Be sure the "S" terminal is snug to the starter solenoid cap.
25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut.
Tighten
Tighten the nut to 2.5 Nm (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.
26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.
Tighten
Tighten the nut to 11 Nm (97 lb in).
30. On 1998 models, remove one of the bolts (2) that attach the starter solenoid to the starter motor. On 1999-2001 models, remove one of the long bolts (1) that hold the starter motor end cap to the housing.
31. On 1998 models, install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall the bolt in the starter solenoid. On 1999-2001 models, install the ground ring terminal (black wire) on the long bolt and reinstall the bolt in the starter.
Tighten
Tighten the starter solenoid bolt or long starter motor bolt to 9 Nm (80 lb in).
32. Reinstall the negative battery cable to the battery.
Tighten
Tighten the bolt to 16 Nm (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.
33. 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.