STARTER MAY CLICK BUT NO CRANK (DIAGNOSTIC PROCEDURE). Chevrolet Lumina 1991

REVISON 11/05/93

THIS BULLETIN IS BEING REVISED TO CHANGE THE PARTS USED IN STEP 3C.

PREVIOUS DIVISIONAL PUBLICATION NUMBERS WERE:

CHEVROLET 93-275-6D PONTIAC 93-8-23 OLDSMOBILE 93-T-85 BUICK 93-6D-3 GM OF CANADA 93-8A-125 ----------------------------------------------------------------------

SUBJECT: STARTER MAY CLICK, BUT NOT CRANK (DIAGNOSTIC PROCEDURE)

MODELS: 1991-93 CHEVROLET LUMINA 1991-93 PONTIAC GRAND PRIX 1991-93 OLDSMOBILE CUTLASS SUPREME 1991-93 BUICK REGAL ENGINES: 3.1L (VIN CODE T) LH0 3.4L (VIN CODE X) LQ1

CONDITION:

WHEN ATTEMPTING TO START THE VEHICLE, THE CUSTOMER MAY HEAR A CLICK, BUT THE STARTER WILL NOT CRANK. THIS CONDITION IS USUALLY INTERMITTENT.

CAUSE:

1. THE CONNECTIONS TO THE STARTER, BATTERY, OR GROUND MAY BE LOOSE OR CORRODED. THE BATTERY MAY ALSO HAVE INSUFFICIENT CHARGE.

2. THE STARTER MOTOR MAY HAVE INSUFFICIENT INTERNAL LUBRICATION AND/OR TOO HIGH DRIVE SPRING FORCE.

3. THE INSTALLATION OF AN AFTERMARKET THEFT ALARM SYSTEM (INCLUDING THE "GOODWRENCH" SYSTEM) MAY ADD ENOUGH ADDITIONAL RESISTANCE TO THE STARTER SOLENOID CIRCUIT TO PREVENT THE STARTER FROM ENGAGING. THE WIRING IN THE ALARM SYSTEM PACKAGE MAY NOT BE ABLE TO CARRY THE TOTAL CURRENT OF THE STARTER SOLENOID CIRCUIT UNDER ALL CONDITIONS.

CORRECTION:

1. IF THE VEHICLE HAS THE "GOODWRENCH" ALARM SYSTEM INSTALLED, REWIRE THE ALARM MODULE CIRCUIT WITH 10 GAGE WIRE. THE INSTRUCTIONS ARE IN THE "ALARM SYSTEM REWORK" PROCEDURE BELOW. IF ANOTHER BRAND OF ALARM HAS BEEN INSTALLED, A SIMILAR REWORK MAY HAVE TO BE DONE TO INSURE THAT THE WIRING FROM THE IGNITION SWITCH TO THE PARK/NEUTRAL SWITCH IS AT LEAST 10 GAGE.

WHEN THE REWIRE STEP IS COMPLETE, CONTINUE WITH STEP 2.

2. CHECK BOTH THE POSITIVE AND NEGATIVE CONNECTIONS AT THE BATTERY, THE BATTERY GROUND TO THE ENGINE BLOCK, AND THE CONNECTIONS TO THE STARTER MOTOR. CHECK THE BATTERY TO INSURE THAT IT IS PROPERLY CHARGED.

3. USING A DIGITAL MULTIMETER, CHECK THE VOLTAGE AT THE STARTER SOLENOID "S" TERMINAL WHILE ATTEMPTING TO START. THIS TEST MUST BE DONE WHILE THE VEHICLE IS EXPERIENCING A "CLICK, NO CRANK", NOT DURING A GOOD START.

IF THE VOLTAGE IS LESS THAN 9.0 VOLTS, CHECK FOR HIGH RESISTANCE IN THE WIRING, CONNECTIONS, IGNITION SWITCH, OR PARK/NEUTRAL SWITCH. IF THE VOLTAGE IS GREATER THAN 9.0 VOLTS, PERFORM THE FOLLOWING STEPS:

NOTE: IF THE STARTER SOLENOID IS HOT TO THE TOUCH, USE 9.5 VOLTS IN THE ABOVE TEST. 9.0 VOLTS SHOULD BE USED IF THE STARTER SOLENOID IS AT ROOM TEMPERATURE.

A. DISCONNECT THE NEGATIVE BATTERY CABLE.

B. REMOVE THE STARTER FOLLOWING SERVICE MANUAL INSTRUCTIONS IN SECTION 6D.

C. REPLACE THE STARTER DRIVE ASSEMBLY WITH P/N 10477566. FOLLOW THE INSTRUCTIONS IN THE SERVICE MANUAL, SECTION 6D2.

WHEN THE STARTER IS BEING REASSEMBLED, APPLY GREASE, P/N 10477434, TO THE INSIDE OF THE SOLENOID CORE, AS SHOWN IN THE ILLUSTRATION. TO APPLY THE GREASE, OPEN ONE PACKET AND APPLY THE CONTENTS EVENLY AROUND THE INSIDE OF THE SOLENOID CORE TUBE, STARTING AT THE OPENING AND COVERING THE FIRST 1/2" (13 MM) OF THE INSIDE OF THE TUBE.

THE GREASE, P/N 10477434, COMES IN A BOX OF 25 ONE GRAM PACKETS, AND ONE PACKET WILL BE USED FOR EACH STARTER SOLENOID.

D. REINSTALL THE STARTER. RECONNECT THE NEGATIVE BATTERY CABLE.

NOTE: IF THE OIL FILTER WAS REMOVED TO REINSTALL THE STARTER, INSTALL A NEW FILTER AND CHECK THE OIL LEVEL.

ALARM SYSTEM REWORK

1. DISCONNECT NEGATIVE BATTERY CABLE. REMOVE AIR CLEANER, AND ON 3.1L ONLY, ROTATE ENGINE FORWARD.

2. REMOVE THE SOUND INSULATOR PANELS FROM BOTH SIDES. REMOVE THE KNEE BOLSTER. LOCATE THE THEFT ALARM MODULE. THIS MODULE IS NORMALLY LOCATED UNDER THE I/P ON THE LEFT, BUT MAY HAVE BEEN INSTALLED IN OTHER LOCATIONS. DISCONNECT CONNECTOR C202 (I/P HARNESS TO STEERING COLUMN). REMOVE TERMINAL FROM CAVITY B6 (YELLOW WIRE). CUT TERMINAL OFF, AND TAPE WIRE BACK. CRIMP AND SOLDER A NEW TERMINAL TO THE NEEDED LENGTH OF 10 GAGE WIRE (ENOUGH TO REACH THE ALARM MODULE), AND INSTALL THE TERMINAL IN THE CONNECTOR. IF THE STARTER CIRCUIT HAS BEEN CUT ON THE STEERING COLUMN SIDE OF C202, USE FEMALE TERMINAL, P/N 12084590. OTHERWISE, USE MALE TERMINAL P/N 12066493. REINSTALL THE CONNECTOR.

3. CRIMP AND SOLDER A NEW TERMINAL, P/N 12084590, TO THE OTHER END OF THE WIRE. INSTALL THIS WIRE TO THE YELLOW/RED TERMINAL OF THE ALARM MODULE.

4. CRIMP AND SOLDER A NEW TERMINAL, P/N 12084590, TO ANOTHER LENGTH OF 10 GAGE WIRE (LONG ENOUGH TO REACH THE PARK/NEUTRAL SWITCH ON THE TRANSAXLE). INSTALL THIS WIRE INTO THE YELLOW TERMINAL OF THE ALARM MODULE.

5. RUN THE WIRE THROUGH THE TRANSMISSION SHIFT CABLE GROMMET (NEXT TO THE CABLE, NOT ON THE OUTSIDE OF THE GROMMET) INTO THE ENGINE COMPARTMENT.

6. RAISE THE VEHICLE. ON 3.4L ONLY, REMOVE THE EXHAUST DOWN PIPE. CRIMP AND SOLDER A NEW TERMINAL, P/N 12052139, WITH CABLE SEAL, P/N 12048443, TO THE NEW WIRE. DISCONNECT THE CONNECTOR TO THE PARK/NEUTRAL SWITCH, AND REMOVE THE TERMINAL FROM CAVITY F. CUT THE OLD TERMINAL OFF, AND TAPE THE WIRE BACK. INSTALL THE NEW TERMINAL INTO THE CONNECTOR, AND REINSTALL THE CONNECTOR. ROUTE AND SECURE THE WIRE TO AVOID ANY RUBBING OR PINCHING. USE SEALER TO INSURE THAT THE FRONT-OF-DASH DOES NOT LEAK WHERE THE WIRE GOES THRU. ON 3.4L, RECONNECT THE EXHAUST DOWN PIPE. LOWER THE VEHICLE.

7. INSTALL THE KNEE BOLSTER, THE SOUND INSULATOR PANELS, AND RECONNECT THE NEGATIVE BATTERY CABLE. ON 3.1L, ROTATE THE ENGINE BACK TO THE ORIGINAL POSITION.

ANY TIME THE NEGATIVE BATTERY CABLE HAS BEEN DISCONNECTED, PERFORM THE RELEARN PROCEDURE FOR THE 3.1L/3.4L ENGINES, USING THE TECH 1 SCAN TOOL.

PART AVAILABILITY:

PARTS ARE EXPECTED TO BE AVAILABLE AT GMSPO BY 11/15/93.

WARRANTY INFORMATION:

REWIRE PROCEDURE:

LABOR OPERATION: T3365 LABOR TIME: 1.5 HRS. (3.1L), 1.7 HRS. (3.4L)

DRIVE ASSEMBLY REPLACEMENT: LABOR OPERATION: J4600 USE PUBLISHED LABOR OPERATION TIME.

FIGURES: 1

Object Number: 93259 Size: MF

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.