transmission CHEVROLET DYNASTY 1993 User Guide

FAN SHROUD
All vehicles have fan shrouds to improve fan air
flow efficiency. These fan shrouds cover less than full
radiator frontal area to prevent the shroud from re-
stricting air flow at high speeds. The shroud supports the electric fan motor and fan.
For removal and installation see Radiator Section.
AUTOMATIC TRANSMISSION OIL COOLERS
Oil coolers are internal oil to coolant type, mounted
in the radiator left tank (Fig. 16). Rubber oil lines
feed the oil cooler and the automatic transmission.
Use only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses
are recommended. Tighten Oil Cooler Hose Clamps
to4N Im (35 in. lbs.).
Fig. 15 Engine Controller 60-Way Connector from
Terminal End
Fig. 16 Transmission Oil Cooler
Ä COOLING SYSTEM 7 - 23

IGNITION OFF DRAW (IOD)
GENERAL INFORMATION
A normal electrical system will draw from 5 to 30
milliamperes from the battery. This is with the ignition
in the OFF position, and all non-ignition controlled cir-
cuits in proper working order. The amount of IOD will
depend on body model and electrical components. A ve-
hicle that has not been operated for an extended period
of approximately 20 days may discharge the battery to
an inadequate level. In this case, the Main Fusible Link
Connector should be disconnected. The Main Fusible
Link connector is located rearward of the battery on the
engine wiring harness (Fig. 19).
If the IOD is over 30 milliamperes, the defect must
be found and corrected before condemning the bat-
tery. Usually, the battery can be charged and re-
turned to service (Fig. 16).
IGNITION OFF DRAW (IOD) TESTS
VEHICLES WITHOUT ELECTRONIC AUTOMATIC TRANSMISSION/LOAD LEVELINGSUSPENSION OR ALARM SYSTEMS
Testing for HIGHER AMPERAGE IOD must be
performed first to prevent damage to most milliamp
meters. A standard 12 volt test light and a milliamp meter
that is equipped with two leads will be used for the
following tests. The milliamp meter should be able to
handle up to two amps.
(1) Verify that all electrical accessories are OFF.
Turn off all lights, close trunk lid, close glove box door,
turn off sun visor vanity lights, close all doors and re- move ignition key. Allow the Illuminated Entry System
if equipped to time out in approximately 30 seconds.
(2) Verify the engine compartment lamp bulb is
working by opening/closing hood. Remove the lamp. (3) Disconnect negative battery cable (Fig. 15).
(4) Connect a typical 12 volt test light between the
negative cable clamp and the negative battery post (Fig.
19). The test light may be brightly lit for up to three
minutes or may not be lit at all. This depending on the
body model or electronic components on the vehicle. (a) The term brightly used throughout the follow-
ing tests. This implies the brightness of the test light
will be the same as if it were connected across the
battery posts. This would be with a fully charged bat-
tery.
(b) The test light or the milliamp meter MUST
be positively connected to the battery post and the
battery cable during all IOD testing. (c) Do not allow the test light or the milliamp
meter to become disconnected during any of the
IOD tests. If this happens, the electronic timer
functions will be started and all IOD tests must be
repeated from the beginning. Clamp the test light
at both ends to prevent accidental disconnection.
(d) After three minutes time has elapsed, the test
light should turn OFF or be dimly lit depending on
the electronic components on the vehicle. If the test
light remains BRIGHTLY lit, do not disconnect test
light. Disconnect each fuse or circuit breaker until
test light is either OFF or DIMLY lit. Refer to the
Front Wheel Drive Car Wiring Diagrams Service
Manual. This will eliminate higher amperage IOD. It
is now safe to install the milliamp meter without
damage to the meter to check for low amperage IOD.
(e) Possible sources of high IOD are usually ve-
hicle lamps trunk lamp, glove compartment, lug-
gage compartment, etc.. (f) If test light is still brightly lit after discon-
necting each fuse and circuit breaker, disconnect
the wiring harness from the generator. Refer to
Generator Testing. Do not disconnect test light.
CAUTION: This last test has higher amperage IOD and
must be performed before going on with low amper-
age IOD tests. The higher amperage IOD must be elim-
inated before hooking up milliamp meter to check for
low amperage IOD. If higher amperage IOD has not
been eliminated, milliamp meter may be damaged.
Most milliamp meters will not handle over one or two
amps. Do not hook up meter if test light is glowing
brightly. Refer to maximum amperage specifications
and instructions supplied with milliamp meter.
After higher amperage IOD has been corrected, low
amperage IOD may be checked. The MAXIMUM IOD=
30 MILLIAMPERES.
Fig. 19 IOD Test
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 9

(5) With test light still connected, connect milli-
amp meter between battery negative post and nega-
tive battery cable (Fig. 20). Do not open any doors or
turn on any electrical accessories with the test light
disconnected and the milliamp meter connected.
Meter may be damaged.
(6) Disconnect test light. Milliamp meter reading
should be less than 30 milliamperes. If low amperage
IOD is not within specifications, disconnect: (a) The 60 way connector at the Powertrain Con-
trol Module located outboard of the battery. Refer
to Group 8D, Ignition for more information. (b) The 25 way connectors on the Body Control-
ler if equipped. (c) The circuits to the clock and radio.
(d) The wiring harness from the generator. Refer
to Generator Testing.
Check each component until excessive IOD is found.
Each time the test light or milliamp meter is dis-
connected and connected, all electronic timer func-
tions will be activated. Tests must be repeated from
the beginning. Test light or meter MUST remain connected for all
tests.
VEHICLES EQUIPPED WITH ELECTRONIC AUTOMATIC TRANSMISSION, LOADLEVELING SUSPENSION, OR ALARM SYSTEM
This vehicles will have temporary high IOD of 15
amps or more for up to 65 minutes. This higher IOD can often mask another problem and should be con-
sidered when performing IOD testing. Testing for higher IOD will be the same as in the
previous IOD tests. However, certain additional pro-
cedures should be followed.
² WITH ALARM SYSTEM: After disconnecting bat-
tery and hooking up test light, cycle the key lock on
the driver's door to disarm the alarm. The parking
lamps should stop flashing. Also locate the Power Distribution Center. This
Center is located in front of the left front strut tower
(Fig. 21). Remove the cover from the Center and re-
move the 50 amp fuse.
² WITH ELECTRONIC AUTOMATIC TRANSMIS-
SION: If equipped with this option, and high or low
IOD is suspected, allow an additional 25 minutes
minimum of electronic shut off time. To defeat the timer, disconnect the 60-way connec-
tor on the Transmission Controller. This controller is
located on the right inner fender.
² WITH AUTOMATIC LOAD LEVELING SYSTEM:
If equipped with this option, and high or low IOD is
suspected, allow an additional 65 minutes minimum
of electronic shut off time. To defeat the timer, open the trunk lid, locate the
Automatic Load Leveling computer, located inside
right rear wheel house, and disconnect the 11-way
connector. Close the trunk lid. If equipped with an electrical trunk closing feature,
temporarily install a heavy gauge jumper wire be-
tween the disconnected negative cable and the nega-
tive battery post. When this jumper is installed the
trunk lid should automatically close. Do not discon-
nect the test light as all electronic timing features
will be activated and all IOD tests must be repeated
from the beginning. Remove the temporarily installed jumper wire.
Fig. 20 Low Amperage IOD Test
Fig. 21 Power Distribution Center
8A - 10 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

STARTER TEST PROCEDURES ON VEHICLE INDEX
page page
Diagnostic Preparation ..................... 11
General Information ....................... 11 Starter Control Circuit Tests
................ 15
Starter Feed Circuit Tests .................. 11
GENERAL INFORMATION
The starting system (Fig. 1) has:
² Ignition switch
² Starter relay (Fig. 2)
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Wiring harness
² Battery
² Starter motor with an integral solenoid
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
less than 20 amps.
DIAGNOSTIC PREPARATION
Before going on with starting system diagnostics,
verify: (1) The battery top, posts, and terminals are clean.
(2) The generator drive belt tension and condition
is correct. (3) The battery state-of-charge is correct.
(4) The battery will pass load test.
(5) The battery cable connections at the starter
and engine block are clean and free from corrosion. (6) The wiring harness connectors and terminals
are clean and free from corrosion. (7) Proper circuit grounding.
(8) Refer to Starter System Diagnostics (Fig. 3).
STARTER FEED CIRCUIT TESTS
The following procedure will require a suitable
volt/ampere tester (Fig. 4).
CAUTION: Ignition system also must be disabled to
prevent engine start while performing the following
tests.
(1) Connect a volt-ampere tester (Fig. 4) to the bat-
tery terminals (Fig. 5). Refer to the operating in-
structions provided with the tester being used. (2) Disable ignition system as follows:
² VEHICLES WITH CONVENTIONAL DISTRIBU-
TORS: Disconnect the ignition coil cable from the
distributor cap. Connect a suitable jumper wire be-
tween the coil cable end-terminal and a good body
ground (Fig. 6).
Fig. 1 Starting Components/Wiring
Fig. 2 Starter Relay
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 11

² VEHICLES WITH DIRECT IGNITION SYSTEM:
Disconnect the ignition coils electrical connector (Fig.
7). (3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in PARK or
manual in NEUTRAL. Set parking brake. (4) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
8). ²
If voltage reads above 9.6 volts, and amperage
draw reads above 250 amps, go to the starter feed
circuit resistance test.
² If voltage reads 12.4 volts or greater and amperage
reads 0 to 10 amps, go to starter control circuit test.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) After the starting system problems have been
corrected, verify the battery state of charge and
charge battery if necessary. Disconnect all testing
equipment and connect ignition coil cable or ignition
coil connector. Start the vehicle several times to as-
sure the problem was corrected.
Fig. 4 Volt Ampere Tester
Fig. 5 Volt-Ampere Tester Connections
Fig. 6 Ground Ignition Coil Cable
Fig. 7 Ignition Coils Electrical Connection
Fig. 8 Starter Draw Tests
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 13

STARTER CONTROL CIRCUIT TESTS
The starter control circuit has:
² Starter solenoid
² Starter relay (Fig. 2)
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Ignition switch
² Battery
² All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition system must be disabled.
² VEHICLES EQUIPPED WITH A CONVEN-
TIONAL DISTRIBUTOR: Disconnect coil wire from
distributor cap center tower. Secure wire to a good
ground to prevent engine from starting (Fig. 6).
² VEHICLES EQUIPPED WITH DIRECT IGNI-
TION SYSTEM: Unplug the coils electrical connector
(Fig. 7).
STARTER SOLENOID TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN PARK OR NEUTRAL WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests. (2) Perform this starter solenoid test BEFORE per-
forming the starter relay test. (3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring. (5) Lower the vehicle.
(6) Locate the starter relay as follows:
² On AC, AG, AJ and AY Bodies the relay is located
in the Power Distribution Center. This Center is mounted near the front of the left front strut tower
(Fig. 13). The position of the starter relay within this
Center will be shown on the Center cover.
² On AA/AP Bodies the relay is located on the front
of the left front strut tower (Fig. 14).
(7) Remove the starter relay from the connector.
(8) Connect a remote starter switch or a jumper
wire between the battery positive post and terminal
87 on the starter relay connector. To decide the
starter relay terminal numbers, refer to the Starter
Relay Tests.
² If engine now cranks, starter/starter solenoid is
good. Go to the starter relay test.
² If engine does not crank with this test, or solenoid
chatters, check wiring and connectors from starter
Fig. 12 Test Positive Battery Cable Resistance
Fig. 13 Starter Relay LocationÐAC, AG, AJ, and AY Bodies
Fig. 14 Starter Relay LocationÐAA/AP Body
Ä BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 15

relay to starter solenoid for loose or corroded connec-
tions. Particularly at starter terminals.
² Repeat test. If engine still fails to crank properly,
trouble is within starter or starter mounted solenoid,
and it must be removed for repairs. Refer to Group
8B, Battery/Starter/Generator Service, Starter re-
placement.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN PARK OR NEUTRAL WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests. (2) Perform the preceding starter solenoid tests
BEFORE performing starter relay tests. Refer to
Starter Solenoid Test. (3) Locate and remove the starter relay. For
starter relay locations, refer to Starter Solenoid Test
(Fig. 13 or 14). (4) After the starter relay has been located and re-
moved, refer to Starter Relay Tests (Fig. 15).
NEUTRAL STARTING AND BACK-UP SWITCH
AUTOMATIC TRANSMISSION ONLY
For electrical diagnostics, when checking starter
circuits, refer to Starter Relay Tests (Fig. 15). For replacement of switch, refer to Group 21, Tran-
saxle, Neutral Starting and Switch Replacement.
STARTER INTERLOCK SWITCHÐCLUTCH PEDAL MOUNTED
MANUAL TRANSMISSION ONLY
For electrical diagnostics, refer to the Starter Relay
Tests. For replacement and/or adjustment of the switch,
refer to Group 6, Manual Transaxle Clutch, Manual
Transaxle Starter Interlock Switch.
IGNITION SWITCH TEST
After testing the starter solenoid and relay, test ig-
nition switch and wiring. Refer to Group 8D, Ignition
Systems, or the Front Wheel Drive Car Wiring Dia-
grams Service Manual. Check all wiring for opens or
shorts, and all connectors for being loose or corroded.
BENCH TESTING STARTER SOLENOID
(1) Disconnect field coil wire from field coil termi-
nal (Fig. 16 or 17). (2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. Con-
tinuity should be detected (Fig. 18 or 19). (3) Check for continuity between solenoid terminal
and solenoid housing (Fig. 20 or 21). Continuity
should be detected. If continuity is detected, solenoid
is good. (4) If continuity is not detected in either test, sole-
noid has an open circuit and is defective. If equipped
with:
² BOSCH STARTER: Replace the solenoid.
² NIPPONDENSO STARTER: Replace the starter
assembly.
8A - 16 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS Ä

STARTER INDEX
page page
General Information ........................ 4
Neutral Starter and Back-Up Switch ........... 8
Starter Component Replacement .............. 5
Starter Interlock Switch: Clutch Pedal Mounted/ Manual Transmission Only ................. 7 Starter Motor Replacement
.................. 4
Starting System ........................... 4
Supply Circuit and Control Circuit ............. 4
GENERAL INFORMATION
This section will cover Starter replacement and
service procedures only. For starter diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics.
STARTING SYSTEM
The starting system has:
² Ignition switch
² Starter relay
² Neutral starting and back-up switch with auto-
matic transmissions
² Clutch pedal mounted starter interlock switch
with manual transmissions
² Wiring harness
² Battery
² Starter motor with an integral solenoid
BOSCH STARTERS
²A Bosch permanent magnet starter motor is avail-
able on 2.2L, 2.5L and 3.0L engines on all vehicles.
A planetary gear train transmits power between
starter motor and pinion shaft. The fields consist of
six permanent magnets.
NIPPONDENSO STARTERS
² A Nippondenso reduction gear-field coil starter
motor is available on 3.0L, 3.3L and 3.8L engines.
SUPPLY CIRCUIT AND CONTROL CIRCUIT
Both starter systems consist of two separate cir-
cuits:
² A high amperage supply to feed the starter motor.
² A low amperage circuit to control the starter sole-
noid. For additional information on starter motor supply
and control circuits, refer to Group 8A, Battery/Start-
ing/Charging Systems Diagnostics.
STARTER MOTOR REPLACEMENT
BOSCH STARTERÐ2.2L/2.5L ENGINE
(1) Disconnect battery negative cable (Fig. 1).
(2) Raise vehicle. (3) Remove heat shield clip from the starter and
heat shield is clipped to starter (Fig. 2). For easier
servicing, do not remove the wiring from starter at
this time.
(4) Remove two bolts and one nut attaching starter
to engine (Fig. 3). (5) Remove starter/starter solenoid assembly from
engine. Position the starter to gain access to the wir-
ing connectors. (6) Disconnect the positive battery cable and wir-
ing at the starter. (7) Remove the starter from vehicle.
Fig. 1 Remove or Install Battery Cable
Fig. 2 Starter Heat ShieldÐ4 Cylinder Engines
8B - 4 BATTERY/STARTER/GENERATOR SERVICE Ä

BOSCH STARTER GEAR AND CLUTCH REPLACEMENT
(1) Remove solenoid assembly (Fig. 18).
(2) Remove the two through-bolts securing the
starter drive end housing to the motor housing (Fig.
19) and separate housings. (3) Remove rubber seal (Fig. 20). (4) Pull the gear and clutch assembly from the
drive end housing (Fig. 21). (5) For installation, reverse above procedures.
STARTER INTERLOCK SWITCH: CLUTCH PEDAL
MOUNTED/MANUAL TRANSMISSION ONLY
For electrical diagnostics, refer to Group 8A, Bat-
tery/Starting/Charging Systems Diagnostics, Starter
relays.
Fig. 13 Gear and Clutch Assembly
Fig. 14 Field Terminal Nut
Fig. 15 Field Coil Terminal
Fig. 16 Field Terminal Washer
Fig. 17 Solenoid Mounting Screws
Fig. 18 Solenoid
Ä BATTERY/STARTER/GENERATOR SERVICE 8B - 7

MECHANICAL/ELECTRONIC CLUSTER REMOVAL
CLUSTER BEZEL REMOVAL
(1) On column shift vehicles, place column shifter
to neutral position. (2) On tilt steering column vehicles, adjust tilt
range to lowest position. (3) Pull cluster bezel rearward to disengage 11
clips (Fig. 10).
(4) Remove cluster bezel.
(5) For installation reverse above procedures.
CLUSTER MASK AND LENS REMOVAL
(1) Remove cluster, radio and rear window defog-
ger bezels (Fig. 10). (2) Remove four cluster to panel screws.
(3) Pull cluster assembly rearward. Vehicles with
column shift use care to not damage transmission
range indicator guide tube. (4) Remove four screws holding the cluster mask to
cluster housing (Fig. 11).
(5) Pull cluster mask and lens rearward to remove.
(6) For installation reverse above procedures.
CLUSTER ASSEMBLY
REMOVALÐCLUSTER WITH TRANSMISSION RANGE
INDICATOR FROM STEERING COLUMN
(1) Disconnect battery to assure no air bag system
fault codes are stored. (2) Remove cluster bezel (Fig. 10).
(3) On column shift vehicle: (Fig. 12 through 15).
(a) Remove lower steering column cover (Fig.
16). Release guide tube from behind fuse block.
Fig. 10 Cluster Bezel
Fig. 11 Cluster Mask and Lens
Fig. 12 Transmission Range Indicator Step 1
Fig. 13 Transmission Range Indicator Step 2
Ä INSTRUMENT PANEL AND GAUGES 8E - 5