1999-2001 J Car - Cavalier/Sunfire With 2.4L (VIN Code T)
1999-2001 J car - Cavalier/Sunfire with 2.4L Engine (VIN Code T)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). If there is not clip, use the prop rod holding clip (5) as a reference for determining the correct location for the J-nut.
7. 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.
8. 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.
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 in) 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
Tighten the bolt to 10 Nm (89 lb in).
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 nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
16. 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 24 and remove the nut. Do NOT perform Steps 17-23 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 17 of this procedure. Steps 17-23 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.
17. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal.
18. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
19. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191 on the short purple wire.
20. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
21. Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
22. 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.
23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
24. Remove the nut from the starter solenoid "S" terminal, and remove all the wires from the terminal.
25. Cut the ring terminal from the vehicle wiring harness purple wire, which was removed from the "S" terminal.
26. 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.
27. 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.
28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.
29. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
30. 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).
31. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
32. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
33. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
34. 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).
35. 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 long bolts (1) that hold the starter motor end cap to the housing.
36. Install the ground ring terminal (black wire) on the harness kit on the ground stud or on the long bolt on the starter motor. Install the nut on the stud or install the long bolt in the starter.
Tighten
^ Tighten the nut to 18 Nm (13 lb-ft).
^ Tighten the long bolt to 9 Nm (80 lb in).
37. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator.
38. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator.
39. Install the air cleaner outlet resonator on the throttle body.
Tighten
Tighten the clamp to 5 Nm (44 lb in).
40. Connect the air cleaner outlet duct to the air cleaner housing.
Tighten
Tighten the clamp to 5 Nm (44 lb in).
41. Connect the electrical connector to the sensor in the air cleaner outlet duct.
42. Install the two 10 mm hex head bolts that secure the air cleaner outlet resonator.
Tighten
Tighten the bolts to 10 Nm (89 lb in).
43. Reinstall the negative battery cable to the battery.
Tighten
Tighten the bolt to 16 Nm (12 lb-ft).
Important:
Do not use a remote start 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.
44. 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, no further action is required.
^ If the starter will NOT crank the engine, skip to Procedure A for J car Cavalier/Sunfire.