CAMPAIGN: POOR ENGINEPERF. START REPAIR/RETAIN ENG. WIRE. Chevrolet Cavalier 1998

NOTE: GM OF CANADA CAMPAIGN 98002 IS LOCATED BELOW THE U.S. VERSION

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: 98002 - POOR ENGINE PERFORMANCE, NO START REPAIR/RETAIN ENGINE WIRING HARNESS/BRANCH

MODELS: CERTAIN 1998 CHEVROLET CAVALIER AND PONTIAC SUNFIRE VEHICLES

THIS BULLETIN SUPERCEDES SERVICE BULLETIN 73-64-06 ISSUED DECEMBER 1997.

General Motors has decided that certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines (RPO LN2) may have either or both of the following conditions:

- A branch of the engine wiring harness may contact the brake master cylinder, damaging the insulation, and causing a short circuit. This can cause poor engine performance, rough idle, no start, the "service engine soon" telltale to come on, or a combination of these symptoms.

- On vehicles equipped with 4-speed automatic transaxles (RPO MN4), the main engine wiring harness may contact the transaxle cooler line bracket, damaging the insulation on one or more of its wires. This can cause a variety of electrical problems which can affect vehicle driveability.

To correct these conditions, dealers are to inspect the involved wiring harness(es) for damage, repair as required, and route and retain the wiring harness(es) to prevent contact with the master cylinder and/or transaxle cooler line bracket.

VEHICLES INVOLVED

Involved are certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines (RPO LN2) and built within the following VIN breakpoints:

IMPORTANT

There are two groups of vehicles involved in this campaign; Group 'A' and Group 'B'.

Group 'A' vehicles all require inspection of the engine wiring harness branch near the brake master cylinder. Vehicles in this group equipped with 4-speed automatic transaxles (RPO MN4) also require inspection of the engine wiring harness near the transaxle cooler line bracket. Damaged wires are to be repaired, and the harnesses are to be retained as described in the service procedure.

Group 'B' vehicles require inspection of the engine wiring harness near the transaxle cooler line bracket only (the engine wiring harness near the brake master cylinder has already been corrected in Group 'B' vehicles). Damaged wires are to be repaired, and the harness is to be retained as described in the service procedure.

Group 'A'

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1998 Chevrolet Cavalier Lordstown 7 W7000001 W7158355 1998 Chevrolet Cavalier Lansing M WM000001 WM120660 1998 Chevrolet Cavalier Genasys B WB000001 WB910330 1998 Chevrolet Cavalier Ramos S WS000001 WS820950 1998 Pontiac Sunfire Lordstown 7 W7000001 W7526909 1998 Pontiac Sunfire Genasys B WB000001 WB200883 1998 Pontiac Sunfire Ramos S WS000001 WS820950

Group 'B'

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1998 Chevrolet Cavalier Lordstown 7 W7158356 W7181162 1998 Chevrolet Cavalier Lansing M WM120661 WM123884 1998 Chevrolet Cavalier Genasys B WB901331 WB901650 1998 Chevrolet Cavalier Ramos S WS820951 WS828700 1998 Pontiac Sunfire Lordstown 7 W7526910 W7536359 1998 Pontiac Sunfire Genasys B WB200884 WB201250 1998 Pontiac Sunfire Ramos S WS820951 WS828700

NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO Customer Special Order.

To ensure availability of the flexible conduit to all involved dealers, dealers are requested to order only one fifteen-foot roll to meet the requirements of this campaign. One roll of P/N 8919355 will service approximately seventy (70) vehicles.

Part Number Quantity/ Description Vehicle

8919355 Conduit-flexible wiring-polyamide-13mm dia 2.5 inches (fifteen foot roll of conduit - will service approximately 70 vehicles)

IMPORTANT: If dealers have one of the following part numbers in stock, it may be substituted for P/N 8919355:

P/N 12125347 Conduit-flexible wiring-polyamide-10mm dia P/N 8919354 Conduit-flexible wiring-polyamide-9mm dia

CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the appropriate divisional customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

SERVICE PROCEDURE

(Skip steps 2 and 3 for Group 'B' vehicles)

1 . Prep vehicle.

2. Inspect the #4 injector/EGR wiring harness branch for damage caused by contact with the RH front corner of the brake master cylinder.

3. If the injector/EGR wiring is damaged, repair as required per Service Manual procedure (section 8A-5).

Install a 60mm (2.5 in.) section of flexible polyamide conduit over the harness. Be sure to capture both the EGR and injector wires. Tape both ends of the conduit.

See figure 1.

4. On vehicles equipped with 4-speed automatic transaxle (RPO MN4), inspect the main engine wiring harness for damage caused by contact with the transaxle cooler line bracket. This bracket is located on the left (driver's) side of the engine compartment, where the transaxle and engine meet, just below the wiring harness.

5. If any wires in the main engine wiring harness are damaged, make repairs per Service Manual procedure (section 8A-5).

Secure the main engine harness to the negative battery cable with a plastic tie strap.

See figure 2.

6. Install the GM Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269- 5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* REPAIR PART FAILED PARTS LABOR LABOR NET PERFORMED COUNT PART NO. ALLOW CC-FC 0P HOURS ITEM

Inspect harnesses As MA-96 V0122 0.2 hr *** for damaged wiring, req'd install conduit and/or tie strap. [No wiring repairs required]

Inspect harnesses As MA-96 V0123 0.4 hr *** for damaged wiring, req'd repair wiring as required, install conduit and/or tie strap. [Wiring repair(s) required]

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

** The amount identified in the "Net Item" column should represent the sum total of the Current GMSPO Dealer Net Price plus 40% for the flexible conduit and plastic tie strap needed to perform the required repairs. P/N 8919355 is a 15 foot roll of flexible conduit, and will service approximately 70 vehicles.

*** For vehicles equipped with three-speed automatic or manual transaxles, the amount in the "Net Item" column will be $0.33. For vehicles equipped with MN4 four-speed automatic transaxles, the amount in the "Net Item" will be $0.47.

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

Dear <Division(s)> Customer:

This notice is sent to inform you of a recall campaign that includes your vehicle.

Reason For This Recall: General Motors has decided that certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines (RPO LN2) may have either or both of the following conditions:

What Will Be Done: To correct these conditions, your dealer will inspect the involved wiring harness(es) for damage, repair as required, and route and retain the wiring harness(es) to prevent contact with the master cylinder and/or transaxle cooler line bracket. This service will be performed for you at no charge.

Contacting Your Dealer: Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you experience any trouble scheduling your vehicle or you have any questions regarding this recall action, please contact the appropriate Customer Assistance/ Relations Center at the listed number below:

Deaf, Hearing Impaired Division Number or Speech Impaired *

Chevrolet 1-800-222-1020 1-800-833-2438 Pontiac 1-800-762-2737 1-800-833-7668

* Utilizes Telecommunication Devices for the Deaf/Text Telephones (TDD/TTY)

Customer Reply Card: The enclosed customer reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

<Division(s)> GENERAL MOTORS CORPORATION

** CANADIAN VERSION **

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: CAMPAIGN 98002 - POOR ENGINE PERFORMANCE, NO START REPAIR/RETAIN ENGINE WIRING HARNESS/ BRANCH

MODELS: 1998 CHEVROLET CAVALIER AND PONTIAC SUNFIRE

THIS BULLETIN SUPERCEDES SERVICE BULLETIN 73-64-06 ISSUED DECEMBER 1997.

DEFECT INVOLVED

General Motors of Canada Limited has decided that certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines (RPO LN2) may have either or both of the following conditions:

VEHICLES INVOLVED

Involved are certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines (RPO LN2) and built within the VIN breakpoints listed below.

IMPORTANT

There are two groups of vehicles involved in this campaign; Group 'A' and Group 'B'.

Group 'A'

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1998 Chevrolet Cavalier Lordstown 7 W7000001 W7158355 1998 Chevrolet Cavalier Lansing M WM000001 WM120660 1998 Chevrolet Cavalier Genasys B WB000001 WB901330 1998 Chevrolet Cavalier Ramos S WS000001 WS820950 1998 Pontiac Sunfire Lordstown 7 W7000001 W7526909 1998 Pontiac Sunfire Genasys B WB000001 WB200883 1998 Pontiac Sunfire Ramos S WS000001 WS820950

Group 'B'

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign, Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from the Inter-Provincial Records. The use of such motor vehicle registration data for any other purpose is a violation of provincial laws. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements.

To ensure availability of the flexible conduit to all involved dealers, dealers are requested to order only one 4.58 metre (fifteen-foot) roll to meet the requirements of this campaign. One roll of P/N 8919355 will service approximately seventy (70) vehicles.

Part Number Description Quantity/Vehicle

8919355 Conduit-flexible wiring-polyamide - 13mm diameter 60mm (4.58 metre (fifteen foot) roll of conduit - will (2.5 inches) service approximately 70 vehicles)

IMPORTANT: If dealers have one of the following part numbers in stock, it may be substituted for P/N 8919355:

P/N 12125347 Conduit-flexible wiring-polyamide - 10mm diameter P/N 8919354 Conduit-flexible wiring-polyamide - 9mm diameter

CUSTOMER NOTIFICATION

All customers of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of customer letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

SERVICE PROCEDURE

(Skip steps 2 and 3 for Group 'B' vehicles)

1 . Prep vehicle.

2. Inspect the #4 injector/EGR wiring harness branch for damage caused by contact with the RH front comer of the brake master cylinder.

3. If the injector/EGR wiring is damaged, repair as required per Service Manual procedure (section 8A-5).

Install a 60mm (2.5 in.) section of flexible polyamide conduit over the harness. Be sure to capture both the EGR and injector wires. Tape both ends of the conduit.

See Figure 1.

4. On vehicles equipped with 4-speed automatic transaxle (RPO NN4), inspect the main engine wiring harness for damage caused by contact with the transaxle cooler line bracket. This bracket is located on the left (driver's) side of the engine compartment, where the transaxle and engine meet, just below the wiring harness.

5. If any wires in the main engine wiring harness are damaged, make repairs per Service Manual procedure (section 8A-5).

Secure the main engine harness to the negative battery cable with a plastic tie strap.

See Figure 2.

6. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the campaign ( number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in by the customer for periodic servicing. Additional Campaign Identification Labels can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

REPAIR PERFORMED PART FAILED PARTS LABOUR LABOUR NET COUNT PART NO. ALLOW CC-FC 0P HOURS ITEM

Inspect harnesses for As Req'd. MA-96 V0122 0.2 hr *** damaged wiring, install conduit and/or tie strap. [No wiring repairs required]

Inspect harnesses for As Req'd. MA-96 V0123 0.4 hr *** damaged wiring, repair wiring as required, install conduit and/or tie strap [Wiring repair(s) required]

* For Campaign Administrative Allowance, add 0.1 hours to the "Labour Hours".

** The amount identified in the "Net Item" column should represent the sum total of the Current GMSPO Dealer Net Price plus 40% for the flexible conduit and plastic tie strap needed to perform the required repairs. P/N 8919355 is a 4.58 metre (15 foot) roll of flexible conduit, and will service approximately 70 vehicles.

*** For vehicles equipped with three-speed automatic or manual transaxles, the amount in the "Net Item" column will be $0.50. For vehicles equipped with MN4 four-speed automatic transaxles, the amount in the "Net Item" will be $0.78.

Refer to the General Motors Claims Processing Manual for details on Product Campaign Claim Submission.

January 1998

Dear General Motors Customer:

General Motors of Canada Limited has decided that certain 1998 Chevrolet Cavalier and Pontiac Sunfire model vehicles equipped with 2.2L 4-cylinder engines may have either or both of the following conditions:

- On vehicles equipped with 4-speed automatic transaxles, the main engine wiring harness may contact the transaxle cooler line bracket, damaging the insulation on one or more of its wires. This can cause a variety of electrical problems which can affect vehicle driveability.

To correct these conditions, your GM dealer will inspect the involved wiring harness(es) for damage, repair as required, and route and retain the wiring harness(es) to prevent contact with the master cylinder and/or transaxle cooler line bracket.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.