Sunfire L4-144 2.4L DOHC VIN T SFI (2001)
upper radiator support bar just to the left (driver side) of the air bag support bracket.
Tighten
Tighten the bolt to 10 Nm (89 lb in).
5.
Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the
clips on the harness.
6.
Raise the vehicle on a suitable hoist.
7.
Remove the nut from the starter solenoid "B" terminal, and removal all wires and the positive battery cable from the terminal.
8.
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 16 and remove the nut. Do NOT
perform Steps 9-15 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 9 of
this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector
before proceeding.
9.
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.
10.
Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
11.
Using an appropriate crimping tool, install one end of butt connector P/N 12089191 on the short purple wire.
12.
Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
13.
Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
14.
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.
15.
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 9-15 proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step
16.
16.
Remove the nut from the starter solenoid "S" terminal, and remove all wires from the solenoid terminal.
17.
Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
18.
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.
19.
Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
20.
Install and crimp 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.
21.
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 9-15 earlier proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT
perform Steps 9-15 earlier, proceed to Step 22.
22.
Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
23.
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
