GM Service Manual
Contents
1. Did you find and correct the condition Starting System Service Manual Go to Step 9 Go to Step 18 Go to Step 11 Go to Step 18 Go to Step 14 Go to Step 21 Go to Step 28 Go to Step 28 Go to Step 22 Go to Step 16 Go to Step 23 Go to Step 12 Go to Step 15 Go to Step 17 Go to Step 19 Go to Step 19 16 17 18 19 20 21 22 23 24 10 Test the control circuit of the CRANK relay for an open or a short to battery voltage Refer to Circuit Testing and Wiring Repairs in Wiring Systems Did you find and correct the condition Go to Step 28 Test the crank voltage circuit of the PCM for an open or high resistance Refer to Circuit Testing and Wiring Repairs in Wiring Systems Did you find and correct the condition Go to Step 28 Inspect for poor connections at the CRANK relay Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 28 Inspect for poor connections at the starter solenoid Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems Did you find and correct the condition Go to Step 28 Inspect for poor connections at the ignition switch Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 28 Inspect for poor connections at2. Cold Cranking Amperage The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold temperatures The cold cranking amperage rating is the minimum amperage the battery must maintain for 30 seconds at 18 C 0 F while maintaining at least 7 2 volts Refer to Battery Usage for the cold cranking amperage rating for this vehicle Starting System Service Manual 2 Battery Inspection Test Tools Required J 42000 Battery Tester Diagnostic Aids Caution Refer to Battery Disconnect Caution in Cautions and Notices Important The battery test using the J 42000 requires correct connections to the battery terminals A failure to obtain the correct connections during the test may result in a failed test on a good battery Follow these instructions in order to avoid an incorrect diagnosis because of connections ftesting the vehicle with the battery cables still connected wiggle the J 42000 clips on the terminal bolt This may cut through any coating or through any oxidation that may be present on the bolt Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit f correct connections to the battery terminal bolts in the vehicle are in doubt perform the following steps Disconnect the negative battery cable Disconnect the positive battery cable Install the test adapters on the terminals Follow the instructions for an Out of Vehicle te
3. ut 3 Install the positive battery cable 9 and the solenoid BAT terminal nut 8 finger tight to the starter motor Install the starter solenoid wire 6 and the starter solenoid S terminal nut 7 finger tight to the starter motor Tighten Tighten the solenoid BAT terminal nut 8 to 10 N m 89 Ib in Tighten the starter solenoid S terminal nut 7 to 2 3 N m 20 5 Ib in 4 Install the torque converter covers Refer to Torque Converter Cover Replacement in Automatic Transaxle 4T65 E 5 Install the lower air deflector Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling 6 Lower the vehicle 7 Connect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection Starting System Service Manual 19 Battery Description and Operation A DANGER POISON SHIELD EYES NO SULFURIC ACID CES EXPLOSIVE i SPARKS S CAN CAUSE GASES FLAME OR BLINDNESS OR OK CAN CAUSE SMOKING SEVERE BURNS BLINDNESS OR INJURY G c PROT GER LES YEUX i TENIR ELOIGNE L ACIDE SULFURIQUE GAZ EXPLOSIF DESETINGELLES PEUT RENDRE AVEUGLE RECYCLE PEUT RENDRE AVEUGLE DES FLAMMES NE OU PROVOQUER DES RECYCLER OU BLESSEH PAS FUMER BRULURES GRAVES RINCER LES YEUX FLUSH EYES IMMEDIATELY et IMMEDIATEMENT A L EAU WITH WATER GET MEDICAL HELP FAST CONSULTER IMMEDIATEMENT UN M DECIN KEEP OUT OF REACH OF CHILDREN TENIR HORS DE LA PORT E DES ENFANTS DO NOT OPEN B
4. counts may indicate a suspect area Modules may be waking up on their own which is most unlikely or activated by a switch input power fluctuation poor ground or input from other modules which are being activated 1 Rh 12 Once it has been determined that the draw is either a component relay switch etc which is stuck or in some way reduces contributes to the draw determine which circuits are specifically involved Touching and or removing fuses relays and connectors to suspect components after reviewing the current wiring diagram until the draw is reduced to acceptable levels will lead to the correct circuit When exiting the message monitor screen and then re entering the message monitor screen the Tech 2 will also wake up modules DON T BE FOOLED Wait for the module s to again go to sleep or use the sleep mode function 13 Back to basics Checking ground credibility requires a voltage drop test under load ALWAYS TEST FROM THE NEGATIVE SIDE OF THE CIRCUIT A voltage drop test is performed at various points along the circuit from the ground side toward the positive side of the circuit until the point of high resistance is located ALWAYS MAKE CERTAIN THAT THE CIRCUIT LOAD IS ON ALWAYS USE A HIGH IMPEDANCE METER LIKE A FLUKE 87 THE HIGHER THE VOLTAGE READING THE HIGHER THE RESISTANCE IN THAT CIRCUIT WHEN TESTING TRY TO ACHIEVE A READING AS CLOSE TO ZERO AS POSSIBLE USUALLY LESS THAN 25 MILLIVOLTS ALWAYS START WITH A
5. 6 Missing gear teeth Milled teeth Is the flywheel bent or does it have damaged teeth Go to Step 9 Go to Step 10 Starting System Service Manual 15 16 10 11 1 Remove the starter motor Refer to Starter Replacement 2 Inspect the starter motor bushings and clutch gear Does the clutch gear have chipped or milled teeth or worn bushings Go to Step 10 Go to Step 9 Shim the starter motor away from the flywheel by adding shims between the starter motor and the engine block one at a time Flywheel runout may make this noise appear to be intermittent Did you complete the repair Go to Step 11 Replace the flywheel Refer to Engine Flywheel Replacement in Engine Mechanical 3 4L or Engine Flywheel Replacement in Engine Mechanical 3 8L Did you complete the replacement Go to Step 11 Replace the starter motor Refer to Starter Replacement Did you complete the replacement Go to Step 11 Operate the system in order to verify the repair Did you correct the condition System OK Go to Step 3 Starting System Service Manual Starter Replacement 3 4L Removal Procedure Important The starter motor on this vehicle is NOT serviceable and must be replaced as a complete unit 1 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnection and Connection 2 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in General Information 3 Remove the lower air
6. deflector Refer to Radiator Air Lower Baffle and Deflector Replacement in Engine Cooling 4 Remove the torque converter covers Refer to Torque Converter Cover Replacement in Automatic Transaxle 4T65 E PTE i EV 5 Remove the starter solenoid BAT terminal nut 8 and the positive battery cable 9 from the starter motor 6 Remove the starter solenoid S terminal nut 7 and the starter solenoid wire 6 from the starter motor Starting System Service Manual 17 ft T 7 Remove the starter bolts 1 2 and the starter motor Installation Procedure 1 Align the starter motor to the engine Notice Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems 18 Starting System Service Manual 2 Install the starter motor bolts 1 2 finger tight until seated Tighten Tighten the bolts to 43 N m 32 Ib ft BER ER WEE ad ex
7. enpoy 014105 UIEINSMOT en Area Aew Burcepu dor POOLISPUSN S UILL Iw TE 19H anual M IVIC Starting Sy c Starting System Description and Operation The PG 260D and PG 260G are non repairable starter motors They have pole pieces that are arranged around the armature Both solenoid windings are energized The pull in winding circuit is completed to the ground through the starter motor The windings work together magnetically to pull and hold in the plunger The plunger moves the shift lever This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the flywheel ring gear on the engine Moving at the same time the plunger also closes the solenoid switch contacts in the starter solenoid Full battery voltage is applied directly to the starter motor and it cranks the engine As soon as the solenoid switch contacts close current stops flowing thorough the pull in winding because battery voltage is applied to both ends of the windings The hold in winding remains energized its magnetic field is strong enough to hold the plunger shift lever starter drive assembly and solenoid switch contacts in place to continue cranking the engine When the engine starts pinion overrun protects the armature from excessive speed until the switch is opened When the ignition switch is released from the START position the START relay opens and battery voltage is removed from the starter solen
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9. the J 38758 Notice Refer to Component Fastener Tightening Notice in Cautions and Notices 22 Connect the battery negative cable to the battery negative terminal Tighten Tighten the negative battery cable terminal bolt to 17 N m 13 Ib ft Starting System Service Manual 33 Subject Class 2 Platform Battery Drain Diagnosis Process Models 1996 2008 Passenger Cars and Light Trucks that use Class 2 Communications The following diagnosis might be helpful if the vehicle exhibits the symptom s described in this PI Condition Concern Platform Battery Drain Diagnosis Process Battery is discharged for no apparent reason while vehicle is parked and locked Intermittent draw and or possible continuous draw s that slowly renders the battery below its serviceable voltage amperage level Please follow this process entirely 1 Define the conditions which trigger the discharged battery How long does it take for the battery to discharge This step will help determine if the draw is large or small Normally a draw which takes the battery level down overnight after operating the vehicle the day before is rather large and is related to a switch relay or other electric mechanical device Small amounts of drain which take several days to take the battery from a good state of charge to below the level required to start the engine can be small single bulbs or modules which are either not going to sleep when they should or waking up inter
10. the PCM harness connectors Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 28 Repair an open or high resistance in the battery positive voltage circuit of the Starter relay coil Refer to Wiring Repairs in Wiring Systems Did you complete the repair Go to Step 28 Repair an open or high resistance in the battery positive voltage circuit of the Starter relay switch Refer to Wiring Repairs in Wiring Systems Is the repair complete Go to Step 28 Replace the CRANK relay Is the repair complete Go to Step 28 Starting System Service Manual Go to Step 21 Go to Step 20 Go to Step 24 Go to Step 25 Go to Step 26 Go to Step 27 25 26 27 28 Replace the starter motor Refer to Starter Replacement Did you complete the replacement Replace the ignition switch Refer to Ignition and Start Switch Replacement in Instrument Panel Gauges and Console Is the repair complete I MPORTANT Perform the set up procedures for the PCM Replace the PCM Refer to Powertrain Control Module Replacement in Engine Controls 3 4L or Powertrain Control Module Replacement in Engine Controls 3 8L Did you complete the replacement Operate the system in order to verify the repair Did you find and correct the condition Starting System Service Manual Go to Step 28 Go to Step 28 Go to Step
11. 28 System OK Go to Step 2 11 Starter Solenoid Clicks Engine Does Not Crank Step Action Yes No Schematic Reference Starting and Charging Schematics Did you perform the Diagnostic System Check for Diagnostic System 1 Engine Electrical Check Engine Electrical Go to Step 2 Turn the ignition switch to the START position 2 Go to Starter Solenoid Did the starter solenoid click one time Does Not Click Go to Step 3 Inspect the engine and belt drive system for mechanical Go to Engine Will Not binding seized engine seized generator Crank Crankshaft Will Not Rotate in Does the engine move freely Engine Mechanical 3 3 4L or Engine Will Not Crank Crankshaft Will Not Rotate in Engine Mechanical 3 8L Go to Step 4 Test the battery positive cable between the battery and the Engine Harness Wiring Junction Block TOP for an open or high resistance Refer to Circuit Testing and Wiring Repairs in Wiring Systems Did you find and correct the condition Go to Step 10 Go to Step 5 Test the battery positive cable between the Engine Harness Wiring Junction Block TOP and the starter motor for an open or high resistance Refer to Circuit Testing and Wiring Repairs in Wiring Systems Did you find and correct the condition Go to Step 10 Go to Step 6 Test the ground of the starter motor between the battery and the starter motor for a high resistance Refer to Circuit Testing and Wiring Repairs in Wiring Systems Di
12. A Automotive Technology STARTING SYSTEM Model 811FJ SERVICE MANUAL 2003 Chevrolet Impala ATech Training Inc 12290 Chandler Drive Walton KY 41094 USA Toll Free 1 888 738 9924 Phone 859 485 7229 Fax 859 485 7299 Email sales Qatechtraining com Website www atechtraining com Copyright 2011 2 Automotive Technology Table of Contents Starting System eau Le 1 Starting System Description and Operation 4 Starter USE vvs eee Ge 5 Diagnostic System Check Engine Electcal esses eene tnnt 6 Starter Solenoid Does NOE Click eek 8 Starter Solenoid Clicks Engine Does Not Crank sse 12 Engine Een ME 14 Starter Noise DEN 15 Starter Replacement 3 4L Lee 17 Battery Description and OP Nea 20 Battery Inspection Test ee 22 Battery Charging e T T 26 Jump Starting in Case or Emergelicy nu 28 Battery Disconnect CT gn ae und on eb ap LO e bla E pa EM ra dn 30 Battery Electrical Drain Parasitic Load Test 31 Platform Battery Drain Diagnosis Process 34 OMA uo Joerg z E TJoUuTeI uo po 0015 GLID F er ERA SSS x I E JOJON WOd joquog T N eels SINPON I Aeey e mu aen d 1 UIEINISMOd e mS ALA lla swals g BAD co 94 SONBUISYoS e uonnquisig punoJe piousjog 19 JOJEJSUSE ei em UH EL wun egen 1SNYSTE 5 OG M18 Sk SLUSIS S Bun ul So meuleuos uonnguisiq wc OG W1d 6L Es 9 Idd 6 3 9 1dd z Q SERO T RV oS so TEX PET va L MI86LI 9 ldd lt S29 M18 13A SEO Asyeg
13. ATTERY NE PAS OUVRIR LA BATTERIE NONSPILLABLE ABSORBENT GLASS MAT BATTERY BATTERIE SCELLEE RECOMBINAISON DE GAZ Caution Batteries produce explosive gases contain corrosive acid and supply levels of electrical current high enough to cause burns Therefore to reduce the risk of personal injury when working near a battery Always shield your eyes and avoid leaning over the battery whenever possible Do not expose the battery to open flames or sparks Do not allow the battery electrolyte to contact the eyes or the skin Flush immediately and thoroughly any contacted areas with water and get medical help Follow each step of the jump starting procedure in order Treat both the booster and the discharged batteries carefully when using the jumper cables Important Because of the materials used in the manufacture of automotive lead acid batteries dealers and service shops that handle them are subject to various regulations issued by OSHA EPA DOT and various state or local agencies Other regulations may also apply in other locations Always know and follow these regulations when handling batteries Batteries that are no longer wanted must be disposed of by an approved battery recycler and must never be thrown in the trash or sent to a landfill Batteries that are not part of the vehicle itself not the battery under the hood must only be transported on public streets for business purposes via approved hazardous material
14. FULLY CHARGED BATTERY Please follow this diagnostic or repair process thoroughly and complete each step If the condition exhibited is resolved without completing every step the remaining steps do not need to be performed GM bulletins are intended for use by professional technicians NOT a do it yourselfer They are written to inform these technicians WE SUPPORT of conditions that may occur on some vehicles or to provide information that could assist in the proper service of a vehicle VOLUNTARY Properly trained technicians have the equipment tools safety instructions and know how to do a job properly and safely Ifa condition is described DO NOT assume that the bulletin applies to your vehicle or that your vehicle will have that condition See TECHNICIAN your GM dealer for information on whether your vehicle may benefit from the information CERTIFICATION 36 Starting System Service Manual
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16. ble connector ring The cable bolt is too long or deformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or cable connector ring Did you complete the repair 10 N m 88 Ib in Go to Step 10 Go to Step 11 Go to Step 10 Go to Step 11 Starting System Service Manual Go to Step 8 11 12 13 14 15 Important Ensure that both battery cables are disconnected and proper adapters are installed in the battery terminals 1 Install the J 42000 2 Follow the directions supplied with the tester for an Out of Vehicle test 3 Follow any directions displayed on the tester 4 If the tester calls for charging the battery refer to Battery Charging Did the tester pass the battery 1 Press the CODE button on the J 42000 2 For warranty purposes write the displayed code on the repair order Did you complete this action 1 Connect the positive battery cable to the battery s positive terminal 2 Notice Refer to Fastener Notice in Cautions and Notices Tighten the positive battery cable bolt to the specified value 3 Connect the negative battery cable to the battery negative terminal 4 Tighten the negative battery cable bolt to the specified value Are the cable bolts properly tightened 1 Press the CODE button on the J 42000 2 For warranty purposes write the displayed code on the repair order Did
17. charge the battery 1 Turn OFF the charger 2 Ensure that all of the battery terminal connections are clean and tight 3 Connect the charger positive lead to the battery positive terminal on the Battery or Fuse Block Underhood 26 Starting System Service Manual Notice Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment The action of the battery charger may damage such equipment 4 Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment that is connected directly to the battery negative terminal but away from the battery If the negative battery cable is disconnected and a terminal adapter is being used connect directly to the adapter 5 Turn ON the charger and set to the highest setting for normal charging 6 Inspect the battery every half hour after starting the battery charger Charge the battery until the taper rate charger indicates that the battery is fully charged Estimate the battery temperature by feeling the side of the battery If it feels hot to the touch or its temperature is over 45 C 125 F discontinue charging and allow the battery to cool before resuming charging 7 After charging test the battery Refer to Battery Inspection Test Starting System Service Manual 27 Jump Starting in Case of Emergency Caution Batteries produce explosive gases Batteries contain corrosive acid Batteries sup
18. ctrical Turn the ignition switch to the START position Does the engine crank 1 Install a scan tool 2 With a scan tool observe the Security Lamp State parameter in the BCM Security Data list 3 Turn the ignition switch to the START position Does the scan tool display On 1 With a scan tool observe the Crank Request Signal parameter in the PCM data list 2 Turn the ignition switch to the START position Does the scan tool display Yes 1 With a scan tool observe the Starter Relay Command parameter in the PCM data list 2 Turn the ignition switch to the START position Does the scan tool display On 1 Turn ON the ignition with the engine OFF 2 Verify that the transmission is in Park or Neutral 3 With a scan tool observe the IMS parameter in the Transmission data list Does the scan tool display Park or Neutral Turn the ignition switch to the START position Do you hear the CRANK relay click Go to Diagnostic System Check Engine Electrical Go to Step 2 Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems Go to Step 3 Go to Diagnostic System Check Theft Deterrent in Theft Deterrent Go to Step 4 Go to Step 5 Go to Step 13 Go to Step 7 Go to Step 6 Go to Transmission Internal Mode Switch Logic in Automatic Transaxle 4T65E Go to Step 7 Go to Step 10 Go to Step 8 Starting System Service Manual 10 11 12 13 14 15 1 T
19. d you find and correct the condition Go to Step 10 Go to Step 7 12 Starting System Service Manual 10 Inspect for poor connections at the Engine Harness Wiring Junction Block TOP Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 10 Inspect for poor connections at the starter motor Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems Did you find and correct the condition Go to Step 10 Replace the starter motor Refer to Starter Replacement Is the repair complete Go to Step 10 Operate the system in order to verify the repair Did you find and correct the condition System OK Starting System Service Manual Go to Step 8 Go to Step 9 Go to Step 2 13 Engine Cranks Slowly Inspect the following items Battery Perform the Battery Inspection Test Refer to Battery Inspection Test Wiring Inspect the wiring for damage Inspect all connections to the starter motor the solenoid the battery and all ground connections Refer to Circuit Testing Wiring Repairs Testing for Intermittent Conditions and Poor Connections Connector Repairs Engine 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 mot
20. e battery The colder the battery is the more time it takes to recharge the battery The charging current accepted by a cold battery is very low at first As the battery warms the charging current will increase Charging Procedure Notice Turn OFF the ignition when connecting or disconnecting the battery cables the battery charger or the jumper cables Failure to do so may damage the ECM PCM or other electronic components Notice Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When charging side terminal batteries with the battery cables connected connect the charger to the positive cable bolt and to a ground located away from the battery When charging side terminal batteries with the battery cables disconnected install the battery side terminal adapters and connect the charger to the adapters Tighten Tighten the battery side terminal adapters to 15 N m 11 Ib ft Use the following procedure to
21. ers on the diagnostic table 4 Lack of communication may be because of a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit The specified procedure will determine the particular condition 5 The symptom list in Symptoms will determine the correct diagnostic procedure to use 6 The presence of DTCs which begin with U indicate some other module is not communicating The specified procedure will collect all the available information before you perform tests Step Perform the Battery Inspection Test Does the battery pass the test 1 Install a scan tool Does the scan tool power up Action Refer to Battery Inspection Test 2 Turn ON the ignition with the engine OFF Important The engine may start during the following step Turn OFF the engine as soon as you have observed the Crank power mode 1 Access the Class 2 Power Mode in the Diagnostic Circuit Check on the scan tool 3 2 Rotate the ignition switch through all positions while observing the Class 2 Power Mode parameter Does the ignition switch parameter reading match the ignition switch position for all switch positions Starting System Service Manual Yes No Go to Step 2 Go to Scan Tool Does Not Power Up in Data Link Communications Go to Step 3 Go to Power Mode Mismatch in Body Control System Go to Step 4 1 Turn ON the ignition with the engine OFF 2 Attempt to com
22. erve capacity Refer to Battery Usage 17 1 Divide the reserve capacity by 4 17 2 Compare this to the multimeter milliampere reading taken in the previous step Starting System Service Manual 17 2 The parasitic current drain should not exceed this number 17 2 Example If a battery has a reserve capacity of 100 minutes the current drain should not exceed 25 mA 18 Check the charging system if the vehicle has an acceptable amount of current drain Refer to Charging System Test Notice The test switch must be in the ON position when removing the fuses in order to maintain continuity in the electrical system This avoids damaging the digital multimeter due to accidental overloading such as a door being opened to change a fuse 19 When the vehicle has an unacceptable amount of parasitic current drain remove each fuse one at a time until the current drain falls to an acceptable level This will indicate which circuit is causing the drain Refer to Power Distribution Schematics in Wiring Systems to diagnose exactly which part of the suspect circuit is causing the parasitic drain In some cases a non fused circuit or component such as a generator is the cause of excessive parasitic current drain 20 Repeat the parasitic current drain test procedure after any repair has been completed to make sure that the parasitic current drain is at an acceptable level 21 When the cause of the excessive current draw has been located and repaired remove
23. ive terminal if the vehicle has one 7 Connect the black negative cable to the negative terminal 3 of the booster battery Caution Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and 28 Starting System Service Manual possible explosion of battery gases 8 The final connection is made to a heavy unpainted metal engine part 4 of the vehicle with the discharged battery This final attachment must be at least 46 cm 18 in away from the dead battery 9 Start the engine of the vehicle that is providing the boost Notice Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes Overheating will damage the starter motor 10 Crank the engine of the vehicle with the discharged battery 11 The black negative cable must be first disconnected from the vehicle that was boosted 4 12 Disconnect the black negative cable from the negative terminal 3 of the booster battery Notice Do not let the cable end touch any metal Damage to the battery and other components may result 13 Disconnect the red positive cable from the positive terminal 1 of the booster battery 14 Disconnect the red positive cable from the remote positive terminal 2 of the vehicle with the discharged battery Starting System Service Manual 29 Battery Disconnect Caution Caution Before
24. male end of the J 38758 to the battery ground terminal Turn the J 38758 knob 1 to the OFF position Install the battery negative cable to the female end of the J 38758 Turn the J 38758 knob to the ON position Road test the vehicle and activate all of the accessories including the radio and the air conditioning M oO tA FW NY Park the vehicle Turn the ignition switch to the OFF position and remove the ignition switch key Starting System Service Manual 31 8 9 Connect a 10 A fused jumper wire to the test switch tool terminals 1 Turn the J 38758 knob to the OFF position The current flows through the jumper wire 10 Wait 1 minute If the fuse blows use an inductive ammeter to locate the current draw 11 Set a digital multimeter to the 10 A scale 12 13 14 15 16 17 32 Connect the digital multimeter to the test switch tool terminals 1 Turn the J 38758 knob to the OFF position The current flows through the digital multimeter Wait I minute Check and record the current reading When there is a current reading of 2 A or less turn the J 38758 knob to the ON position The electrical current will now pass through the switch Then switch the digital multimeter down to the 2 A scale for a more accurate reading when the J 38758 knob is turned OFF Turn the J 38758 knob to the OFF position Wait at least 20 minutes Check and record the current reading Note the battery res
25. mittently for some unknown reason How many times has it happened to the customer This step will determine if this is a Random occurrence and or intermittent Does it always happen in the same location Is there some outside influence that surrounds the vehicle that needs to be taken into account This is most unlikely but worth checking out Describe the customer s driving habits Does the battery get to a state of being fully charged on a regular basis or is this vehicle unable to crank due to a generally low state of charge Is the vehicle equipped with any non original equipment including cell phone remote starter extra lighting radio CD player LOJAK etc or OnStar either dealer or factory installed AII of these items can be wired in such a way to either constantly draw amperage which they shouldn t or in some way affect the class 2 modules on this vehicle and or the battery and charging system Does the customer leave the key in the ignition Leaving the key in the ignition does not generally cause a problem but if the customer does not come back to the locked ignition position after shutting the engine off however many draws will be induced This draw will not be reduced and or eliminated this type of draw is due to the fact that the system is designed to keep certain modules awake with the key in this position What is the previous history on this car what parts have been replaced what repairs have been performed either in a
26. municate with each of the following modules on the class 2 serial data circuit Body Control Module BCM Instrument Panel Cluster IPC Powertrain Control Module PCM Body Control Module BCM Instrument Panel Cluster IPC Powertrain Control Module PCM Go to Scan Tool Does Not Does the scan tool communicate with all modules on the class 2 serial data circuit 1 Select the Display DTCs function for each module If using a Tech 2 use the Class 2 DTC Check feature in order to determine which modules have DTCs set 2 Record all of the displayed DTCs the DTC status and the module which set the DTC Does the scan tool display any DTCs Does the scan tool display any DTCs which begin with a U Does the scan tool display DTC B1000 B2947 B2948 B2957 B2058 B2960 B3031 or B3032 Communicate with Class 2 Device in Data Link Communications Go to Step 5 Go to Symptoms Engine Electrical Go to Step 6 Go to Scan Tool Does Not Communicate with Class 2 Device in Data Link Communications Go to Step 7 Go to Diagnostic Trouble Code DTC List in Body Control Go to Diagnostic Trouble System Code DTC List Starting System Service Manual Starter Solenoid Does Not Click Step Action Yes No Schematic Reference Starting and Charging Schematics Connector End View Reference Master Electrical Component List in Wiring Systems Did you perform the Diagnostic System Check for Engine Ele
27. n attempt to correct this situation or that might impact it Are there any other reported problems with the vehicle which may relate to a discharged battery concern items which were previously reported corrected and or currently exist that the customer car recently bought used does not recognize as a problem or the used car manager reporting the discharged battery is unaware of Recent repairs may or may not relate to draw diagnosis i e the IPC was replaced recently 2 Perform a good visual and physical inspection of the battery cables CHECK TORQUE OF BATTERY CABLE BOLTS If loose check for signs of arcing and corrosion etc grounds and power leads to and from each of these or BOLT MATERIAL IN BATTERY THREADS THERMISTOR if equipped CONNECTOR FOR PROPER SEATING AND TIGHTNESS What are the results of a battery CHARGING SYSTEM test Perform a generator output test and a terminal drag test on generator terminal L Fuses related to this concern check for loose fuses in trunk and engine compartment bussed electrical center by rocking each fuse with one finger which may help identify the fuse The only repairs that may be made to the electrical center are replacement of plug in devices and mounting hardware as follows fuses relays circuit breakers electrical center cover battery stud cover and other snap on covers cover attachment thumb screw labels for fuse relay identification splash shields and mounting brackets 34 Starting Sy
28. oid S terminal Current flows from the motor contacts through both windings to the ground at the end of the hold in winding However the direction of the current flow through the pull in winding is now opposite the direction of the current flow when the winding was first energized The magnetic fields of the pull in and hold in windings now oppose one another This action of the windings along with the help of the return spring causes the starter drive assembly to disengage and the solenoid switch contacts to open simultaneously As soon as the contacts open the starter circuit is turned off Circuit Description Moving the ignition switch to the start position sends a 12 volt signal through the PCM CRANK fuse in the Junction Block Left I P to the PCM to notify the PCM that a crank status has been requested 12 volts is fed through the ABS PCM fuse in the Junction Block Left I P to the coil side of the CRANK RLY relay The PCM grounds this circuit when all parameters are met for starting the engine This closes the CRANK RLY relay allowing Battery Positive voltage through Fusible Link and through the switch side of the CRANK relay to the S terminal of the starter solenoid Ground is found through the engine block 4 Starting System Service Manual Starter Usage MEM wm PG260 D L36 PG260 G Starting System Service Manual Diagnostic System Check Engine Electrical Test Description The numbers below refer to the step numb
29. or Refer to Starter Replacement 14 Starting System Service Manual Starter Noise Diagnosis Diagnostic Aids Inspect the flywheel ring gear for damage or unusual wear Shim the starter as required n order to add pinion to ring gear clearance a full size shim must be used Do not shim only one starter mounting bolt There are three shims available in different shapes for clearance all are I mm 0 039 in thick Step Action Yes No Did you perform the Diagnostic System Check Go to Diagnostic 1 System Check Engine Electrical Go to Step 2 Start the engine Go to Testing for Intermittent 2 Does the starter operate normally Conditions and Poor Connections in Wiring Systems Go to Step 3 Start the engine while listening to the starter motor turn 3 sthere a loud whoop it may sound like a siren if the engine is revved while the starter is engaged after the engine starts but while the starter is still held in the engaged position Go to Step 6 Go to Step 4 Do you hear a rumble a growl or in some cases a 4 knock as the starter is coasting down to a stop after starting the engine Go to Step 7 Go to Step 5 Important This is often diagnosed as a starter drive gear hang in or a weak solenoid When the engine is cranked do you hear a high pitched whine after the engine cranks and starts normally Go to Step 8 Go to Step 7 Inspect the flywheel ring gear for the following Chipped gear teeth
30. performing a combination parasitic draw test while monitoring the class 2 devices on the vehicle 1 Remove terminal 16 from data link connector DLC 2 Install tool J38758 on battery 3 Connect Fluke 87 to J38758 as described in the Engine Electrical section of the appropriate Service Manual and set to appropriate amp scale 4 Connect Tech 2 to DLC 5 Connect 110 volt power supply to DLC end of Tech 2 cable 6 Turn Tech 2 on Main enter Diagnostics enter Year Vehicle type Diagnostic circuit check Class 2 message monitor remember only modules which are currently communicating on the Class 2 data line will show up on the message monitor screen If the ignition is in the accessory position as an example the PCM and ABS controller will not be listed If a module which the vehicle is known to be equipped with does not show up on message monitor when in the run position this indicates a problem that needs correction prior to proceeding 7 Allow the vehicle to sit with all doors closed and without activating any switches etc until the class 2 system has had enough time to power down less than 25 minutes or use the sleep mode to put all the modules to sleep Once the sleep mode is enabled the first module to wake up will be listed first on the message monitor screen with others listed in order Starting System Service Manual 35 of wake up The time from being put to sleep until the first wake up sequence will al
31. ply levels of electrical current high enough to cause burns Therefore in order to reduce the risk of personal injury while working near a battery observe the following guidelines Always shield your eyes Avoid leaning over the battery whenever possible Do not expose the battery to open flames or sparks Do not allow battery acid to contact the eyes or the skin Flush any contacted areas with water immediately and thoroughly Get medical help Notice This vehicle has a 12 volt negative ground electrical system Make sure the vehicle or equipment being used to jump start the engine is also 12 volt negative ground Use of any other type of system will damage the vehicle s electrical components 1 Position the vehicle with the booster battery so that the jumper cables will reach Do not let the 2 vehicles touch Make sure that the jumper cables do not have loose ends or missing insulation 2 Place an automatic transmission in PARK If equipped with a manual transmission place in NEUTRAL and block the wheels 3 Turn OFF all electrical loads on both vehicles that are not needed 4 Turn OFF the ignition on both vehicles 5 Connect the red positive cable to the battery positive terminal 2 of the vehicle with the discharged battery Use a remote positive terminal if the vehicle has one 6 Connect the red positive cable to the positive terminal 1 of the booster battery Use a remote posit
32. ry Go to Step 14 Go to Step 8 Starting System Service Manual 23 10 24 Use a torque wrench in order to verify the torque to loosen the positive battery terminal bolt Is the torque above the specified value 1 Disconnect the negative battery cable 2 Disconnect the positive battery cable 3 Clean and wire brush the lead face of both battery terminals and the metal contact rings in both cable connectors 4 Remove the bolts from the cable connectors in order to provide access to the connector rings as needed 5 If either of the battery terminals or the cable rings are excessively damaged or corroded replace as needed Did you complete the repair 1 Disconnect the negative battery cable 2 Inspect for the following conditions and repair as needed The cable bolt is too long or deformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or cable connector ring The cable bolt is too long or deformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or cable connector ring Did you complete the repair 1 Disconnect the positive battery cable 2 Inspect for the following conditions and repair as needed The cable bolt is too long or deformed at the end There is foreign material present inside the nut in the battery terminal Damage to the battery terminal face or ca
33. servicing any electrical component the ignition key must be in the OFF or 30 LOCK position and all electrical loads must be OFF unless instructed otherwise in these procedures If a tool or piece of equipment could come into contact with a live exposed electrical connection then it is advisable to also disconnect the negative battery cable Failure to follow these precautions may cause personal injury and or damage to the vehicle or its components Starting System Service Manual Battery Electrical Drain Parasitic Load Test Tools Required J 38758 Parasitic Draw Test Switch Caution Refer to Battery Disconnect Caution in Cautions and Notices Notice Do not turn the parasitic draw test switch to the OFF position with the engine running Damage will occur to the vehicle s electrical system Notice The test switch must be in the ON position when removing the fuses in order to maintain continuity in the electrical system This avoids damaging the digital multimeter due to accidental overloading such as a door being opened to change a fuse Important The switch knob 1 on the J 38758 is marked ON and OFF When the switch knob is in the ON position the circuit is closed and electrical current will pass through the switch When the switch knob is in the OFF position the circuit is open and electrical current will not pass through the switch Disconnect the battery negative cable from the battery negative terminal Install the
34. so be displayed If a combination of three or four modules has come active putting all of the modules back to sleep and pulling the fuse to one module at a time will help to narrow down which module may be waking up inadvertently Remember that module wake up can be caused by several factors They include but are not limited to input changing states door switch going open and closed hi lo power or ground coming and going to module module internal function incorrect Or in the case of the power master amperage draws in excess of low power requirements or another module which has these or other related concerns These all can be checked with the Fluke set to 1 millisecond record speed on min max setting 8 Open the gate on J38758 and let vehicle sit for another ten 10 minutes and or use sleep mode 9 Review the amperage reading 10 As the amperage draw tapers down below 10 amps close the J38758 and switch Fluke 87 to milliamp scale and record min max on 100 millisecond scale Open the J38758 again when done This step will allow the Fluke meter to record any spikes and keep the meter working during the entire sequence IF MIN MAX IS NOT SELECTED THE METER WILL TIME OUT AND SHUT OFF After the vehicle has been tested for a minimum of 8 hours check the number of counts as per message monitor for each control module i e each time a unit goes from inactive to active and inactive again The module s with the highest number of
35. st f the tester displays a REPLACE BATTERY or BAD CELL REPLACE result for a battery tested in the vehicle with the battery cables connected perform the following steps Disconnect the negative battery cable Disconnect the positive battery cable Install the tester adapters Follow the instructions for an Out of Vehicle test Replace the battery only if the Out of Vehicle test shows a REPLACE BATTERY or BAD CELL REPLACE result This prevents battery replacements that are due only to faulty battery cable connections Use the correct terminal adapters Do not use any common bolts or a combination of bolts nuts and or washers as adapters when testing the battery Use the test adapters that are provided with the J 42000 or P N 12303040 terminal adapters If the adapters that are provided with the J 42000 require replacement use DIN 12303040 Any other adapter may not contact the correct areas of the battery terminal causing a resistance that may result in an invalid battery test result Step Action Values Yes No Caution Refer to Battery Disconnect Caution in Cautions and Notices Important Always write the test code displayed by the tester on the repair order for any warranty purposes The number is a unique code that describes the test data for a particular battery at a particular time The test code may occasionally repeat when you retest the same battery More often each test will 22 Starting System Service Man
36. stem Service Manual 3 What DTCs are currently present or have been recorded on previous visits to the dealer Correct as per the appropriate service manual 4 Road test vehicle for 30 40 minutes activate all accessories Open and close all doors windows deck lid etc CYCLE LUMBAR AND SEAT SWITCHES along with all other manually operated switches including the trunk release fuel door release garage door opener and valet that have power to them all the time while the car is sitting Don t forget to look FOR A STUCK SWITCH RELAY 5 What is the parasitic draw on the vehicle after a 25 minute power down cycle Using parasitic draw test switch tool J38758 and DVOM J39200 perform a parasitic draw test as per the procedure in the Engine Electrical section Service Information Record the draw and read the reserve capacity of the battery in the vehicle Divide the reserve capacity by four 4 and the draw present should not exceed this number Example If the battery has a reserve capacity of 100 amperes the current draw should not exceed 25 mA on the DVOM See SI for acceptable draw limits for each module the vehicle may be equipped with Keep in mind the draw created by the OnStar system for the first 48 hours from ignition off OnStar typical power consumption ANALOG The system will cycle every 10 minutes and cause a spike to approximately 250 mA for about ten seconds taper down to 75 mA for another 45 seconds and go to less than one mA for
37. the nine minutes until the next cycle begins This is normal The Class 2 data line should not wake up during this sequence This cycle stops if power is removed from the OnStar system for a short period and will resume once the GPS signal is reacquired DIGITAL The system will remain in DIGITAL STANDBY for the full 48 hours after the last ignition cycle Normally a tech will see a drain that is reading approximately 20 to 70mA with occasional spikes will vary around 175mA IMPORTANT In digital mode the OnStar module is capable of receiving incoming calls and readings may jump to 250mA or more during the call The call will normally be only a few seconds in duration tis vital to monitor the power consumption and not rely on only the MIN MAX readings on the DVOM The duration of the OnStar cycle should reflect the above information A steady reading no toggle fluctuation in digital standby is abnormal 6 If the draw above is determined to be above the appropriate amount for the vehicle involved are any modules on the class 2 data line staying active past the 25 minute time out mentioned above or waking up periodically after this time out has passed If one or more module is waking up how many times and which module s Use the Tech 2 and use the message monitor screen with an external power source to the Tech 2 if performing an amp draw test while using message monitor Recommendation Instructions Here is a suggested procedure for
38. transportation procedures Battery storage charging and testing facilities in repair shops must meet various requirements for ventilation safety equipment material segregation etc The maintenance free battery is standard There are no vent plugs in the cover The battery is completely sealed except for 2 small vent holes in the side These vent holes allow the small amount of gas that is produced in the battery to escape 20 Starting System Service Manual The battery has 3 functions as a major source of energy Engine cranking Voltage stabilizer Alternate source of energy with generator overload The battery specification label example below contains information about the following The test ratings The original equipment catalog number The recommended replacement model number CATALOG NO CCA LOAD TEST 770 380 REPLACEMENT MODEL 100 6YR Battery Ratings A battery has 2 ratings Reserve capacity Cold cranking amperage When a battery is replaced use a battery with similar ratings Refer to the battery specification label on the original battery or refer to Battery Usage Reserve Capacity Reserve capacity is the amount of time in minutes it takes a fully charged battery being discharged at a constant rate of 25 amperes and a constant temperature of 27 C 80 F to reach a terminal voltage of 10 5 volts Refer to Battery Usage for the reserve capacity rating of the original equipment battery
39. ual result in a different code If the battery is replaced due to failing the test only an Out of Vehicle test code is valid for warranty purposes Inspect the battery for a cracked broken or damaged case which may be indicated by 1 battery acid leakage Is the battery OK Go to Step 2 Go to Step 15 Compare the cold cranking amperage CCA and reserve capacity RC of the battery to the original battery or original equipment OE 2 specification Refer to Battery Usage Does the battery meet or exceed the specifications Go to Step 3 Go to Step 15 1 Turn OFF the ignition 2 Attempt to rotate the negative battery cable connector clockwise with light finger pressure Does the negative connector rotate Go to Step 4 Go to Step 5 Use a torque wrench in order to verify the torque to loosen the negative battery terminal 4 bolt 10 N m 88 Ib in Is the torque above the specified value Go to Step 9 Go to Step 8 Attempt to rotate the positive battery cable connector clockwise with light finger pressure Does the positive connector rotate Go to Step 7 Goto Step 6 Important Ensure that all of the electrical loads are turned OFF 1 Install the J 42000 Battery Tester 6 2 Follow the directions supplied with the tester for an In Vehicle test 3 Follow any directions displayed on the tester 4 If the tester calls for charging the battery refer to Battery Charging Did the tester pass the batte
40. urn OFF the ignition 2 Disconnect the CRANK relay 3 Turn ON the ignition with the engine OFF 4 Connect a test lamp between the battery positive voltage circuit of the CRANK relay coil and a good ground Does the test lamp illuminate 1 Connect a test lamp between the battery positive voltage circuit of the CRANK relay coil and the control circuit of the CRANK relay 2 Turn the ignition to the START position Does the test lamp illuminate 1 Turn OFF the ignition 2 Disconnect the CRANK relay 3 Connect a test lamp between the battery positive voltage circuit of the CRANK relay switch circuit and a good ground Does the test lamp illuminate Connect a 40 amp fused jumper between the battery positive voltage circuit of the CRANK relay switch circuit and the supply voltage circuit of the CRANK solenoid Does the engine crank Did the fuse in the jumper open 1 Turn OFF the ignition 2 Disconnect the PCM 3 Connect a test lamp between the crank voltage circuit of the PCM and a good ground 4 Turn the ignition to the Start position Does the test lamp illuminate Test the supply voltage circuit of the starter solenoid for a short to ground Refer to Circuit Testing and Wiring Repairs in Wiring Systems Did you find and correct the condition Test the supply voltage circuit of the starter solenoid for a high resistance or open Refer to Circuit Testing and Wiring Repairs in Wiring Systems
41. you complete the replacement Replace the battery Refer to Battery Replacement Did you complete the replacement Go to Step 12 Go to Step 13 15 N m 11 Ib ft Battery OK Battery OK Battery OK Starting System Service Manual Go to Step 15 25 Battery Charging Tools Required J 42000 Battery Tester For best results use an automatic taper rate battery charger with a voltage capability of 16 volts The charging area should be well ventilated Do not charge a battery that appears to be frozen Allow the battery to warm to room temperature and test it using the J 42000 before charging Charging Time Required The time required to charge a battery will vary depending upon the following factors The battery charger capacity The higher the charger s amperage the less time it will take to charge the battery The state of charge of the battery A completely discharged battery requires more than twice as much charging time as a half charged battery In a discharged battery with a voltage below 11 volts the battery has a very high internal resistance and may only accept a very low current at first Later as the charging current causes the acid content to increase in the electrolyte the charging current will increase Extremely discharged batteries may not activate the reversed voltage protection in some chargers Refer to the manufacturers instructions for operating this circuitry The temperature of th
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