Starting System: Other Pontiac Sunfire I

STARTER MOTOR USAGE

STARTER MOTOR USAGE

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Check for intermittent or poor connections.

CHECKING AFTERMARKET ACCESSORIES

Do not connect aftermarket accessories into the following circuits

1. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
2. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.

Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems.

Possible causes of vehicle problems related to aftermarket accessories include

1. Power feeds connected to points other than the battery.
2. Antenna location.
3. Transceiver wiring located too close to vehicle electronic modules or wiring.
4. Poor shielding or poor connectors on antenna feed line.
5. Check for recent service bulletins detailing installation guidelines for aftermarket accessories.

STARTER SOLENOID DOES NOT CLICK

Note. To identify system wiring schematics, see SCHEMATIC & ROUTING DIAGRAMS .

1. Did you perform the DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)? If yes, proceed to next step. If no, see «DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)»(ref-168596-S40917223642004111200000) .
2. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition to the START position. Is the security indicator flashing? If yes, see DOOR LOCKS & ANTI-THEFT SYSTEMS. If no, proceed to next step.
3. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition to the START position. Did the engine crank? If yes, test for intermittent or poor connections. If no, proceed to next step.
4. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition to the START position. Does the starter solenoid click? If yes, see «STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK»(ref-168596-S16831014302004111500000) . If no, proceed to next step.
5. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition from the ON to START position several times. Does the crank relay click each time the ignition is placed in the START position? If yes, go to step 8 . If no, proceed to next step.
6. Turn off ignition. Disconnect the crank relay. Connect a test lamp between the crank voltage circuit of the crank relay coil and a good ground. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition to the START position. Does the test lamp illuminate? If yes, proceed to next step. If no, go to step 9 .
7. Connect a test lamp between the crank voltage circuit of the crank relay coil and the ground circuit of the crank relay coil. Depress the clutch pedal or verify the transmission is in park or neutral. Turn the ignition to the START position. Does the test lamp illuminate? If yes, go to step 27 . If no, go to step 30 .
8. Does the vehicle have an automatic transmission? If yes, go to step 10 . If no, go to step 17 .
9. Does the vehicle have a manual transmission? If yes, go to step 15 . If no, go to step 21 .
10. Turn off the ignition. Disconnect the crank relay. Connect a test lamp between the battery positive voltage circuit of the crank relay switch and a good ground. Does the test lamp illuminate? If yes, proceed to next step. If no, go to step 31 .
11. Install a scan tool. Turn on ignition, with engine off. Place the transmission in park or neutral. With a scan tool, observe the TR switch parameter in the PCM data list. Does the scan tool display park or neutral? If yes, proceed to next step. If no, go to step 25 .
12. Turn off ignition. Apply the parking brake and verify the transmission is in park or neutral. Connect a 30 amp fused jumper between the battery positive voltage circuit of the crank relay switch circuit and the crank voltage circuit of the PNP switch. Does the engine crank? If yes, go to step 27 . If no, proceed to next step.
13. Disconnect the PNP switch. Connect a test lamp between the crank voltage circuit of the PNP switch and ground. Does the test lamp illuminate? If yes, proceed to next step. If no, go to step 32 .
14. Connect a test lamp between the crank voltage circuits of the PNP switch. Does the test lamp illuminate? If yes, go to step 25 . If no, go to step 23 .
15. Turn off ignition. Install the crank relay. Disconnect the Clutch Pedal Position (CCP) switch. Connect a 3 amp fused jumper between the crank voltage circuits of the CPP switch. Depress the clutch pedal. Turn the ignition to the START position. Does the engine crank? If yes, go to step 26 . If no, proceed to next step.
16. Remove the jumper. Connect a test lamp between the crank voltage circuit of the CPP switch and ground. Turn the ignition to the START position. Does the test lamp illuminate? If yes, go to step 29 . If no, go to step 20 .
17. Turn off ignition. Disconnect the crank relay. Connect a test lamp between the battery positive voltage circuit of the crank relay switch and a good ground. Does the test lamp illuminate? If yes, proceed to next step. If no, go to step 31 .
18. Turn off ignition. Apply the parking brake and verify the transmission is in park or neutral. Connect a 30 amp fused jumper between the battery positive voltage circuit of the crank relay switch circuit and the crank voltage circuit of the starter solenoid. Does the engine crank? If yes, go to step 27 . If no, proceed to next step.
19. Does the fuse in the jumper open? If yes, go to step 22 . If no, go to step 23 .
20. Test the crank voltage circuit of the CCP switch for a high resistance or an open. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 24 .
21. Test the crank voltage circuit of the crank relay coil for a high resistance or an open. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 24 .
22. Test the crank voltage circuit of the starter solenoid for a short to ground. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 28 .
23. Test the crank voltage circuit of the starter solenoid for a high resistance or an open. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 28 .
24. Inspect for poor connections at the ignition switch. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 33 .
25. Inspect for poor connections at the PNP switch. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 34 .
26. Inspect for poor connections at the CCP switch. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 35 .
27. Inspect for poor connections at the crank relay. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 36 .
28. Inspect for poor connections at the starter solenoid. Did you find and correct the condition? If yes, go to step 38 . If no, go to step 37 .
29. Repair the high resistance or open in the crank voltage circuit of the crank relay coil. When complete, go to step 38 .
30. Repair the high resistance or open in the ground circuit of the crank relay coil. When complete, go to step 38 .
31. Repair the high resistance or open in the battery positive voltage circuit of the crank relay switch. When complete, go to step 38 .
32. Repair the high resistance or open in the crank voltage circuit of the PNP switch. When complete, go to step 38 .
33. Replace the ignition switch. See STEERING COLUMNS. When complete, go to step 38 .
34. Replace the PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-151429-S03849267152002121900000) . When complete, go to step 38 .
35. Replace the CCP switch. See CLUTCHES. When complete, go to step 38 .
36. Replace the crank relay. When complete, go to step 38 .
37. Replace the starter motor. See «STARTER MOTOR»(ref-168596-S06417425402004111500000) . When complete, proceed to next step.
38. Operate the system for which the symptom occurred. Is the symptom still present? If yes, go to step 2 . If no, system is okay.

STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK

Note. To identify system wiring schematics, see SCHEMATIC & ROUTING DIAGRAMS .

1. Did you perform the DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)? If yes, proceed to next step. If no, see «DIAGNOSTIC SYSTEM CHECK (ENGINE ELECTRICAL)»(ref-168596-S40917223642004111200000) .
2. Turn the ignition to the START position. Did the starter solenoid click? If yes, proceed to next step. If no, see «STARTER SOLENOID DOES NOT CLICK»(ref-168596-S30146945742004111500000) .
3. Inspect the engine and belt drive system for mechanical binding, seized engine, or seized generator. Does the engine move freely? If yes, proceed to next step. If no, see «ENGINE WILL NOT CRANK (CRANKSHAFT WILL NOT ROTATE)»(ref-168596-S26857243932004111700000) .
4. Test the battery positive cable between the battery and the starter solenoid for high resistance. Did you find and correct the condition? If yes, go to step 8 . If no, proceed to next step.
5. Test the ground circuit between the battery and the starter motor for a high resistance. Did you find and correct the condition? If yes, go to step 8 . If no, proceed to next step.
6. Inspect for poor connections at the starter. Did you find and correct the condition? If yes, go to step 8 . If no, proceed to next step.
7. Replace the Starter. See «STARTER MOTOR»(ref-168596-S06417425402004111500000) . When complete, proceed to next step.
8. Operate the system for which the symptom occurred. Did you correct the condition? If yes, system is okay. If no, go to step 2 .

Seized Accessory Drive System Component

1. Remove accessory drive belts.
2. Rotate crankshaft by hand at the balancer or flywheel location.

Hydraulically Locked Cylinder

Note. Some causes of this include coolant/antifreeze in cylinder, oil in cylinder or fuel in cylinder.

1. Remove spark plugs and check for fluid.
2. Inspect for broken head gasket.
3. Inspect for cracked engine block or cylinder head.
4. Inspect for a sticking fuel injector.
5. Inspect for cracked cylinder wall.

Seized Manual Transmission

1. Disengage the clutch.
2. Rotate crankshaft by hand at the balancer or flywheel location. See MANUAL.

Broken Timing Chain And/Or Gears

Inspect timing chain and gears. Repair as required.

Seized Balance Shaft

Inspect balance shaft. Repair as required.

Material In Cylinder

Note. Some causes of this include broken valve, piston material, foreign material, or cracked cylinder wall.

Inspect cylinder for damaged components and/or foreign materials. Inspect for fallen cylinder wall. Repair or replace as required.

Seized Crankshaft Or Connecting Rod Bearings

Inspect crankshaft and connecting rod bearings. Inspect for fallen cylinder wall. Repair as required.

Bent Or Broken Connecting Rod

Inspect connecting rods. Repair as required.

Broken Crankshaft

Inspect crankshaft. Repair as required.

ENGINE CRANKS SLOWLY

Inspect the following items

1. Perform the Battery Inspection/Test. See «BATTERY TESTING & INSPECTION»(ref-167574-S16492984082004101800000) .
2. Inspect the wiring for damage. Inspect all connections to the starter motor, the solenoid, the battery, and all ground connections.
3. Verify that the engine is not seized.

If the battery, the wiring, and the engine are functioning properly, and the engine continues to crank slowly, replace the starter motor. See

STARTER MOTOR