Question about 1997 Pontiac Sunfire

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Charging system, alternator

Charging system, I have 97 Pontiac Sunfire 2.4 liter SE I just bought the car from a friend. Here's my problem batteries keeping dying on me I thought I had a short somewhere or that something was connected wrong and was drawing a lot of power. one day i decided to pop the hood and really get dirty and figure out what was going on. Here's what I found. I have a voltage regulator mounted to the firewall, the alternator itself is jimmy rigged with lines 2 lines running from the inside the alternator where the brushes would be I suppose to the voltage regulator that's mounted to the firewall. I know this had to be the problem and I assumed that the alternator was shot. I took the alternator off and had it tested and it was shot. Now my problem is this because of the way it was hooked up which was 1 line from the battery to the back of the alternator and then it had 2 lines from inside the alternator run to the voltage regulator mounted on the firewall. Then from the voltage regulator mounted on the firewall those 2 lines ran from the firewall to the interior of the car somewhere underneath the driver side dash. Now that I have a new alternator I know that I cant connect it to the voltage regulator on the firewall because the new alternator actually works but now I'm lost as to whats suppose to connect to the harness connector on the alternator because I don't have any connector that fits within the engine compartment. I'm assuming that when they jimmy rigged the alternator they did away with the wiring harness. my question is this what else besides the main line battery to alternator connects to the alternator I'm referring to the harness connector that's has 4 pins ? reason I ask is because I intend to having the harness made I just need to know from the alternator to where ?

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Some friend...... have a repair shop check it out and fix the wiring like its supposed to be. it going to be costly, more than just replacing the alt in the first place.

Posted on Jun 04, 2010

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Need information on 2000 Pontiac Sunfire charging system


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My 2005 Pontiac Sunfire has had several problems over the past couple of months. When I was driving all my gages went to zero when I would start to break. After I started moving again they would go up....


Your car's symptoms (voltage fluctuations under load that shouldn't happen) seem to
strongly indicate that your voltage regulator has failed. The voltage regulator is the component
that regulates voltage coming from the alternator, and which is supplied to the rest of the car.
Your new belt tensioner indicates to me (and should have to your mechanic) that the
alternator and/or voltage regulator weren't able to operate properly, and a faulty belt tensioner
has killed more than one car's alternator/voltage regulator.
Your do not need new headlights. Do fix the turn signals.

In the 2005 Sunfire, the voltage regulator is an integral component of the alternator, and is
not separately serviceable. So your 2005 Sunfire needs a new alternator.

2005 Pontiac Sunfire Alternator - Duralast Part Number: DL2305-15-4 $199.99 available at:
http://www.autozone.com/autozone/parts/2005-Pontiac-Sunfire/Alternator/_/N-jmqtpZ93xme

The national parts chains (Advance Auto Parts, AutoZone, Pep Boys) will (for free) administer
a "Charging System Test." Which will telly you for sure that your alternator/voltage regulator
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Just in case, Here's the 2005 Sunfire manual entry on (a) Diagnosis & testing the alternator, and
(b) replacement of the alternator

Alternator replacement is a do-it-yourself project, though you may need to get a
"Serpentine Belt Kit" on your favorite parts store's loan-a-tool program to remove/re-install the serpentine (drive) belt.
======================================================================
Diagnosis & Testing - 2005 Pontiac Sunfire Alternator


Alternator Load Test

1. With the engine running, turn on the blower motor and the high beams ( or other electrical accessories to place a load on the charging system).

2. Increase and hold engine speed to 2000 rpm.

3. Measure the voltage reading at the battery.

4. The voltage should increase at least 0.5 volts from the voltage test. If the voltage does not meet specifications, the charging system is malfunctioning.
NOTE
Usually under and overcharging is caused by a defective alternator, or its related parts (voltage regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.




Alternator No-Load Test

1. Connect a tachometer to the engine.
CAUTION
Ensure that the transmission is in Park and the emergency brake is set. Blocking a wheel is optional and an added safety measure.


2. Turn off all electrical loads (radio, blower motor, wipers, etc.)

3. Start the engine and increase engine speed to approximately 1500 rpm.

4. Measure the voltage reading at the battery with the engine holding a steady 1500 rpm. Voltage should have raised at least 0.5 volts, but no more than 2.5 volts.

5. If the voltage does not go up more than 0.5 volts, the alternator is not charging. If the voltage goes up more than 2.5 volts, the alternator is overcharging.
NOTE
Usually under and overcharging is caused by a defective alternator, or its related parts (regulator), and replacement will fix the problem; however, faulty wiring and other problems can cause the charging system to malfunction. Many automotive parts stores have alternator bench testers available for use by customers. An alternator bench test is the most definitive way to determine the condition of your alternator.


6. If the voltage is within specifications, proceed to the next test.



Voltage Test

1. Make sure the engine is OFF , and turn the headlights on for 15-20 seconds to remove any surface charge from the battery.

2. Using a DVOM set to volts DC, probe across the battery terminals.

3. Measure the battery voltage.

4. Write down the voltage reading and proceed to the next test.



Removal & Installation - 2005 Pontiac Sunfire Alternator


2.2L (VIN 4) Engines

1. Before servicing the vehicle, refer to the precautions section.

2. Remove or disconnect the following:

Negative battery cable

Accessory drive belt

Alternator mounting bolts

Alternator electrical connectors

Alternator





To install:

1. Before servicing the vehicle, refer to the precautions section.

Alternator. Torque the upper bolts to 37 ft. lbs. (50 Nm) and the lower bolt to 22 ft. lbs. (30 Nm).

Alternator electrical connectors

Accessory drive belt

Negative battery cable





2.2L (VIN F) Engines

1. Before servicing the vehicle, refer to the precautions section.

2. Remove or disconnect the following:

Negative battery cable

Accessory drive belt

Alternator mounting bolts

Alternator electrical connectors

Alternator





To install:

1. Install or connect the following:

Alternator. Torque the bolts to 16 ft. lbs. (22 Nm).

Alternator electrical connectors

Accessory drive belt

Negative battery cable

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