Cavalier, Sunfire 2001-2005

Starter

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air inlet duct
     
    Top starter bolt
     
    Lower starter bolt
     
    Starter electrical connectors
     
    Starter motor

    Click image to see an enlarged view

    Fig. Exploded view of the starter motor-2.4L engine

     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Torque the bolts to 66 ft. lbs. (90 Nm) for 2.4L engine or 37 ft. lbs. (50 Nm) for the 2.2L (VIN 4) engine or 30 ft. lbs. (40 Nm) for the 2.2L (VIN F) engine.
     
    Starter electrical connectors
     
    Air inlet duct to the throttle body
     
    Negative battery cable
     

  2.  

Solenoid or Relay



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the starter motor from the vehicle and place on a clean work surface.
  4.  
  5. Disconnect the solenoid-to-starter lead wire.
  6.  
  7. Remove the solenoid mounting bolts and slide out the solenoid. Pull out the solenoid torsion spring, if so equipped. On some models, it may be necessary to remove the starter assembly through bolts from the yoke to remove the solenoid.
  8.  
  9. If equipped with shims between the solenoid and starter, remove and place aside.

    Click image to see an enlarged view

    Fig. Remove the nut attaching the solenoid cable



    Click image to see an enlarged view

    Fig. Starter solenoid components

  10.  

To install:

  1. Install the solenoid with any adjustment shims.
  2.  
  3. Torque the bolts to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the starter-to-solenoid electrical lead.
  6.  
  7. Install the starter through-bolts if removed.
  8.  
  9. Install the starter motor.
  10.  
  11. Check for proper operation.
  12.  

Testing & Troubleshooting



Voltage Drop Test

NOTE
The battery must be in good condition and fully charged prior to performing this test.

  1. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  2.  
  3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  4.  
  5. Turn the ignition key to the START position and note the voltage on the meter.
  6.  
  7. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  8.  
  9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  10.  
  11. Turn the ignition key to the START position and note the voltage on the meter.
  12.  
  13. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
    NOTE
    Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

  14.  

 
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