Crank no start: How to locate, remove and install the crankshaft position sensor on a 2.4L GM Quad Four

     While changing a starter in a 1997 Pontiac Grand with the 2.4L quad four engine, I had an unexpected encounter with the crankshaft position sensor. So I decided to make a blog post to show how to find, remove and install this small but important part. The 2.4L quad four engine is found in such models as the Pontiac Grand Am and Sunfire, Chevrolet Cavalier and Malibu, Oldsmobile Achieva and Alero and the Buick Skylark built between 1996 and 2002.

Troubleshooting

     With a crank, no start issue, it is good idea to check if there is any gas getting to the cylinders. Remove the coil assembly and then a spark plug from the engine and have a helper try to start the engine while looking for a sign of gas in the hole.

There is no gas getting to the cylinder

      We have no gas at all.

Location

     On the 2.4L Quad Four engine this sensor is located near the oil filter, right behind the end of the starter. It turns out that I was rather careless when pulling out the starter. I caught the wiring or plug on the starter and pulled it out of the sensor. Later, with all parts reassembled, I found to my surprise that the car would crank but not start. I found this loose disconnected plug hanging there and traced it back to this sensor.

Now where does that go?

The location of the switch, underside view

Removal

1) Jack it up and put it on ramps or stands

2) Disconnect the battery. We have to move the starter out of the way and don't want to accidentally touch the B+ terminal on something and make a big spark.

3) It is going to greatly improve access so remove the air intake ducting up to the throttle body and the cooling fan from behind the radiator. See this related blog post for pictures and instructions:
http://www.originalmechanic.com/2015/10/how-to-replace-starter-in-gm-24l-quad.html     

4) Put down a catch pan and spin out the oil filter.

5) Unbolt the starter and carefully set it down out of the way without unwiring it. The sensor will now be in plain sight and readily removable.

The crankshaft position sensor exposed

6) Unbolt the switch with an 8mm socket or wrench. Twist it back and forth while pulling it outward. 

7) My sensor is actually good but will need to have a means attached to lock the wiring in place. The little protrusion that holds the plug was damaged earlier. 

The sensor removed

Installation

1) Place the sensor back in the hole in the engine and rotate to line up with the mounting bolt.. It my be helpful to plug it in ahead of installation as this could be awkward later. 

2) Turn the 8mm bolt back in snugly. 

3) Remount the starter, being careful to avoid any contact with the switch or wiring. 

4) Remount the oil filter. Add some fresh oil if necessary.

5) Remount the cooling fan.

6) Remount the air intake assembly.

7) Remount the spark plug coil assembly if removed

8) Rewire up the battery.

9) Test start the car. 

How to replace the rear wiper motor on a Dodge Caravan, Plymouth Voyager or Chrysler Town and Country 1997-2003

    This post will cover replacing the rear wiper motor and applies to many 1997 to 2003 Chrysler Corp. minivans such as the Dodge Caravan, Plymouth Voyager and Chrysler Town and Country. I struggled mightily on a 2000 Dodge Grand Caravan to simply remove the wiper arm, as it was seized onto the motor shaft. Next the inside lift gate cover or liner must be removed. Finally, the motor is accessible. I have also included is a section on troubleshooting.

                                                       The job at a glance

• Tools: Philips screwdriver, large straight blade screwdriver, right angle or stubby phillips screwdriver, 10mm socket and ratchet. 
• Materials: none
• Parts: wiper motor  
• Cost of parts: motor
• Time: 1 hour

                                                         Removal

1)  Remove the wiper arm from the motor shaft. I think it's a good idea to mark the position first with a piece of masking tape. My 2000 Caravan uses a bolt-less mount to hold the arm in place. Pivot the arm upward and then use a large flat blade screwdriver to pry up the locking lever. This lever must be all the way up before the arm is free to pull off. I found mine to be corroded to the shaft. Some models use a nut on a threaded motor shaft.

The first step of removing the wiper arm proved challenging on this van

2) Remove the lift gate inside trim cover. This may vary a bit from model year to model year. On the 2000, first remove the inside lift handle (2 phillips screws).Then pry up on the cover over the rear brake light. When it is off there will be two phillips screws visible. The one on the left requires a stubby or right angle screwdriver to remove. Now lift the gate and from the outside remove 5 phillips screws.Next, with the gate up, give a good tug from each end to unsnap the panel fasteners. To avoid having the panel hang from the wiring for the inside courtesy lights close the gate. From the inside unplug the two lights. There are red locking clips on the connectors that must be released first. Remove the panel. 

3) Unplug the motor.

Troubleshooting

    Let's do a test to confirm that the motor is bad. While the motor is the most likely cause of the rear wiper not working, it isn't the only one. The best way to isolate the motor and confirm that it's getting power is to measure the voltage at the end of the connector that plugs into the motor. There are three wires on this connector:

                                    Black: Ground
                                    Brown/pink: Ignition 12V
                                    Brown/light green: wiper control 12V

Testing for the ignition 12V (black and brown and pink wires)

                           

                                                        

    Stick an appropriate size wire into the socket for the black wire (ground) and connect to the negative of your meter. Likewise connect the,meter to the Brown/pink wire and check for 12V with the ignition on. Finally, check the Brown/light green wire for 12V with the rear wiper turned on. If all is good at the end of the connector, the motor is bad. If these voltages are not present, the motor is good and the trouble is elsewhere, possibly a fuse or wiring or relay.

We have power at motor control...bad motor

4) Remove the motor. Remove the three 8mm mounting bolt.

                                                            Installation    

1) Mount the replacement motor with the three 8mm replacement. Make sure the rubber bushings remain in place. Snug up the bolts but do not over-tighten.

2) Plug the motor back in.

3) Mount the lift gate trim cover. Start from inside. First plug in the courtesy lights. Make sure to lock the red locking tab. Now flex the panel outward to get it to fit under the side pillars. Snap the panel fasteners into position on each side with a good hearty push. Screw down the top cover and snap the brake light cover back in place. Install the handle with the two phillips screws. Now open the gate and install the five outer screws.

4) Install the wiper arm. Put some anti-seize lubricant on the motor shaft and the contact surface inside the arm.  Slip it over the motor shaft so that the blade aligns with the tape on the rear glass. Lock it down into place. 

5) Test operation. Good job!