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-jmqtpZ93xmeThe 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
is bad. Do this before replacing alternator, since its a pricy part in the 05 Sunfire.
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
×