QuestionThis year model had recall for a starter relay to be added, it's located on top of radiator. Where do the 4 wires go?
AnswerHi John. the wires are ground small black wire. a red wire is constant battery power a another red or yellow that it the start wire input to the relay and a purple wire goes to the starter solenoid. I'm not 100% sure on that 1 wire that is red or yellow. this is the recall:
Remove the two 10mm hex head bolts that secure the air cleaner outlet resonator to the throttle body.
2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct.
3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing.
4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body.
5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body.
Object ID: 866909Click here for detailed picture of the image.
6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit.
7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit.
Tighten
Tighten the screw to 10 Y (89 lb in).
8. On the harness kit, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
10. Route the new wiring harness down to the starter motor.
11. Remove the top starter bolt.
12. Raise the vehicle on a suitable hoist.
13. Remove the oil filter.
14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace.
15. Remove the bottom starter bolt and remove the starter.
16. Remove the nut from the “B” terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
17. 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 25 and remove the nut. Do NOT perform Steps 18-24 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 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.
18. 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.
19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
20. Using an appropriate crimping tool, install one end of the butt connector, P/N 12089191, on the short purple wire.
21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
22. Strip back the insulation about 6.35 mm (1/4 in) on the red wire.
23. 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.
24. 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 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25.
25. Remove the nut from the starter solenoid “S” terminal and removal all wires from the terminal.
26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness.
28. Using an appropriate crimping tool install 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.
29. 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 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Steps 18-24 earlier, proceed to Step 30.
30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
31. 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 Y (22 lb in).
Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.
32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.
Tighten
Tighten the nut to 11 Y (8 lb ft).
Object ID: 866905Click here for detailed picture of the image.
36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor.
37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter.
Tighten
Tighten to 9 Y (79 lb in).
38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time.
39. Lower the vehicle.
40. Install the upper starter bolt.
Tighten
Tighten the bolt to 90 Y (66 lb ft).
41. Raise the vehicle.
42. Tighten the lower starter bolt.
Tighten
Tighten the bolt to 90 Y (66 lb ft).
43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold.
Tighten
◦Tighten the two bolts attaching the brace to the intake manifold to 24 Y (18 lb ft).
◦Tighten the two bolts to the engine block to 26 Y (19 lb ft).
44. Install a new oil filter.
45. Lower the vehicle.
46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator.
47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator.
48. Install the air cleaner outlet resonator on the throttle body.
Tighten
Tighten the clamp to 5 Y (44 lb in).
49. Connect the air cleaner outlet duct to the air cleaner housing.
Tighten
Tighten the clamp to 5 Y (44 lb in).
50. Connect the electrical connector to the sensor in the air cleaner outlet duct.
51. Install the two 10mm hex head bolts that secure the air cleaner outlet resonator.
Tighten
Tighten the bolts to 10 Y (89 lb in).
52. Reinstall the negative battery cable to the battery.
Tighten
Tighten the bolt to 16 Y (12 lb ft).
Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.
53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.
◦If the starter cranks the engine 6 times in a row, proceed to the next step.
◦If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark
54. Check the engine oil level and add as necessary.
55. Install the GM Recall Identification Label.
