Starting System Chevrolet Cavalier III

DESCRIPTION & OPERATION

When ignition switch is turned to START position, battery voltage is applied to Park/Neutral Position (PNP) switch (automatic transaxle) or Clutch Pedal Position (CPP) switch (manual transaxle). Current passes through PNP or CPP switch then on to starter solenoid only when vehicle is in Park or Neutral position (automatic transaxle) or clutch pedal is depressed (manual transaxle). When voltage is applied to solenoid windings, this creates movement of solenoid plunger and shift lever, causing drive pinion to engage flywheel and close solenoid switch contacts. (Scheme 1) When solenoid switch contacts close, starter motor energizes and cranks engine. As engine starts, pinion overrun clutch protects armature from excessive speed until ignition switch is opened and plunger return spring disengages pinion.

Scheme 1

COMPONENT LOCATIONS

COMPONENT LOCATIONS

TROUBLE SHOOTING

Note. For information not covered in this article, see TROUBLE SHOOTING article in GENERAL INFORMATION.

TROUBLE SHOOTING HINTS

Note. Refer to appropriate wiring diagram to verify wire color and connector terminal identification. See WIRING DIAGRAMS .

Note condition and operation of THEFT SYSTEM indicator light. If indicator stays on or flashes continuously, see appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT. Check starter solenoid terminals and battery grounds. Check for proper installation of aftermarket electronic equipment. Check IGN (50-amp) fuse in underhood junction block. See COMPONENT LOCATIONS . Perform self-diagnostic system test to be certain no trouble codes are stored in PCM memory which may lead to misdiagnosis. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

STARTER NOISE

Note. Always check flywheel ring gear for signs of damage.

1. Start engine while observing noise from starter motor. If a noise other than a loud, siren-like "whoop" sound is heard after engine starts, go to next step. If a loud, siren-like "whoop" sound is heard after engine starts, go to step 6 .
2. If a noise other than a "rumble", "growl" or "knock" sound is heard as starter is coasting to a stop after starting engine, go to next step. If a "rumble", "growl" or "knock" sound is heard as starter is coasting to a stop after starting engine, go to step 4 .
3. If a noise other than a high-pitched whine is heard while cranking engine, go to next step. If a high-pitched whine is heard while cranking engine, distance between starter pinion and flywheel is too small. Shim starter away from flywheel by adding shims one at a time and rechecking operation. Ensure starter-to-engine bolts are tightened correctly. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system__torque-specifications) .
4. Remove starter. See «STARTER»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Inspect starter motor bushings and clutch gear. If clutch gear shows signs of chipped or milled teeth or starter motor has worn bushings, go to next step. If starter checks okay, go to step 6 .
5. Replace starter as necessary. During initial starter motor installation, shim(s) are not used. If shim(s) are present, install shim(s) in original location with replacement starter. Ensure starter-to-engine bolts are tightened correctly. See «TORQUE SPECIFICATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system__torque-specifications) .
6. Check flywheel ring gear for chipped, missing or milled teeth. Replace flywheel as necessary. See appropriate AUTOMATIC TRANSMISSION REMOVAL or MANUAL TRANSMISSION REMOVAL article in AUTOMATIC TRANSMISSIONS or MANUAL TRANSMISSIONS. If flywheel checks okay, go to step 5 .

ON-VEHICLE TESTING

Information is not available from manufacturer.

SYSTEM TESTS

Note. The following tests assume that engine and battery are operating normally and are at operating temperature, battery is charged, there are no engine problems that would cause a no-start condition, and no diagnostic trouble codes are present.

SLOW OR NO CRANK ONLY AFTER EXTENDED PERIODS OF VEHICLE NON-USE

There may be a parasitic load on electrical system. See PARASITIC LOAD EXPLANATION & TEST PROCEDURES article in GENERAL INFORMATION.

ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK

1. On vehicles equipped with automatic transaxle, ensure shift lever is in Park. On vehicles equipped with manual transaxle, ensure clutch pedal is depressed. On all vehicles, disconnect Purple wire at "S" terminal of starter solenoid. See «WIRING DIAGRAMS»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system). Connect DVOM between ground and Purple wire at starter solenoid "S" terminal. Turn ignition switch to START position while observing DVOM reading. If battery voltage exists, go to step 4. If battery voltage does not exist, go to next step on vehicles equipped with automatic transaxle and go to step 3 on vehicles equipped with manual transaxle.
2. Turn ignition off. Locate and disconnect Park/Neutral Position (PNP) switch. See «COMPONENT LOCATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system__component-locations). Connect DVOM between ground and Gray 7-pin PNP switch connector C2 terminal "G" (Yellow wire). (Scheme 2) Turn ignition switch to START position while observing DVOM reading. If battery voltage exists, go to step 5. If battery voltage does not exist, go to step 6.
3. Locate and disconnect Clutch Pedal Position (CPP) switch. See «COMPONENT LOCATIONS»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system__component-locations). Ensure shift lever is in Neutral. Connect fused jumper wire between CPP switch connector terminals. With DVOM still connected between ground and Purple wire at starter solenoid "S" terminal, turn ignition switch to START position while observing DVOM reading. If battery voltage exists, replace CPP switch and retest operation. If battery voltage does not exist, go to step 7.
4. Check starter motor ground circuit for high resistance. Repair as necessary and retest operation. If starter motor ground circuit tests okay, replace starter. See «STARTER»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system) under REMOVAL & INSTALLATION.
5. Using DVOM, measure resistance between PNP switch terminals "E" and "G". If 0-2 ohms exist, go to step 9. If 0-2 ohms do not exist, go to step 10.
6. Gain access to ignition switch electrical connector. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Connect DVOM between ground and Natural 6-pin ignition switch connector C1 terminal "C" (Yellow wire). (Scheme 3) Turn ignition switch to START position. If battery voltage exists, repair open in Yellow wire between Natural ignition switch connector C1 terminal "C" and PNP switch (automatic transaxle) or CPP switch (manual transaxle). If battery voltage does not exist, go to step 8.
7. Connect DVOM between ground and CPP switch connector terminal "A" (Yellow wire). Turn ignition switch to START position while observing DVOM reading. If battery voltage exists, go to step 9. If battery voltage does not exist, go to step 6.
8. Connect DVOM between ground and Black 6-pin ignition switch connector C2 terminal "B" (Red wire). (Scheme 4) If battery voltage exists, go to step 11. If battery voltage does not exist, go to step 12.
9. Repair open or high resistance in Purple wire between starter solenoid "S" terminal and PNP switch connector C1 terminal "E" (automatic transaxle) or CPP switch connector terminal "B" (manual transaxle). Retest operation.
10. Check operation and adjustment of PNP switch. See appropriate AUTOMATIC TRANSMISSION SERVICING article in AUTOMATIC TRANSMISSIONS. Repair as necessary and retest operation. If PNP switch adjustment and operation are okay, replace PNP switch and retest operation.
11. Replace ignition switch. See appropriate STEERING COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. Retest operation.
12. Repair open in Red wire between ignition switch connector C2 terminal "A" and IGN (50-amp) fuse located in underhood bussed electrical center. Retest operation.

Scheme 2

Scheme 3

Scheme 4

ENGINE DOES NOT CRANK, SOLENOID CLICKS

1. Inspect engine and drive belt system for mechanical binding. Repair as necessary. If engine moves freely, go to next step.
2. Check for high resistance in positive battery cable between battery and starter solenoid (Red wire). Repair as necessary and retest operation. If battery cable checks okay, go to next step.
3. Check for high resistance in ground circuit between battery and starter. Repair as necessary and retest operation. If ground circuit checks okay, go to next step.
4. Check for poor connections at starter solenoid. Repair as necessary and retest operation. If connections to starter solenoid check okay, go to next step.
5. Replace starter. See «STARTER»(/chevrolet/cavalier/iii-1995-2005/remont/starter/#starting-system) under REMOVAL & INSTALLATION. Retest operation.

BENCH TESTING

Information not available from manufacturer.

REMOVAL & INSTALLATION

Note. Vehicles are designed for starter mounting without shims. A single shim or double shims may have been added to correct a noise or engagement condition. When installing starter, any previously installed shims should be replaced in original location to ensure proper pinion to flywheel clearance.

Removal (2.2L)

Disconnect negative battery cable. Raise and support vehicle. Remove starter mounting bolts. Position engine wiring harness aside as necessary. Disconnect starter solenoid wiring. Remove shims and note arrangement for reassembly (if equipped). Remove starter assembly.

Removal (2.4L)

Disconnect negative battery cable. Remove air inlet duct-to-throttle body. Remove top starter bolt. Raise and support vehicle. Remove lower starter bolt. Position engine wiring harness aside. Disconnect starter solenoid wiring. Remove starter assembly.

Installation (2.2L & 2.4L)

Before installing starter onto engine, tighten inner solenoid terminal nuts to ensure they are secure in cap. Starter failure may occur due to terminal or cap damage. Install positive battery cable and wiring to solenoid terminals. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

OVERHAUL

Note. Starter assemblies are not serviceable and should be replaced as complete units.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• WIRING DIAGRAMS
• COMPONENT LOCATIONS
• TORQUE SPECIFICATIONS