Product Emission Recall - OBDII Misfire Monitor-Reprogram PCM

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2004 Chevrolet Malibu model vehicles equipped with 3.5L V6 (RPO LX9 - VIN Code 8) engine. These vehicles were built with a condition that incorrectly disables the On-Board Diagnostic (OBD) misfire monitor above 35 mph.

Dealers are to reprogram the Powertrain Control Module (PCM).

Involved are certain 2004 Chevrolet Malibu model vehicles equipped with 3.5L V6 (RPO LX9 - VIN Code 8) engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall 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 recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

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

The service calibration is included in TIS 2000 data version 9.5, broadcast to dealers via GM Access on September 8, 2003; and on TIS 2000 CD-ROM version 10, scheduled for mailing to dealers on September 26, 2003.

1. Prep the vehicle for Powertrain Control Module (PCM) reprogramming.
2. Program the PCM using TIS 2000 data version 9.5, broadcast to dealers via GM Access on September 8, 2003, or TIS 2000 CD-ROM version 10, scheduled for mailing to dealers on September 26, 2003. Refer to up-to-date Techline equipment user instructions.
3. CALIFORNIA VEHICLES ONLY: Complete a "Proof of Correction Certificate" upon campaign completion.
4. Install the GM Recall Identification Label.

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

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

Customers will be notified of this recall on their vehicles by General Motors (see copy customer letter included with this bulletin).

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

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

Dealers are to service all vehicles subject to this recall 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 customer letter accompanying this bulletin. Recall 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 recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.

Additional Certificates can be obtained, at no charge, from Dealer Support Materials by calling 1-866-700-0001 (Monday through Friday, 8:00 am to 5:00 pm EST). Ask for GM Item Number 1825 when ordering.

Dear Chevrolet Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

Your vehicle is equipped with an improperly functioning on-board emission-related diagnostic system that violates California and Federal standards and regulations. These vehicles were built with a condition that incorrectly disables the On-Board Diagnostics (OBD) misfire monitor above 35 mph.

Your dealer will reprogram the Powertrain Control Module (PCM). This service will be performed for you at no charge . Eligibility for the PCM reprogramming will not be denied solely due to your vehicle having non-GM parts or repairs performed by outlets other than GM franchised dealers.

This service correction will take approximately 30 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Please contact your Chevrolet dealer as soon as possible, after September 8, 2003, to arrange a service date. 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 Chevrolet Customer Assistance Center at 1-800-630-2438. The deaf, hearing impaired, or speech impaired should call 1-800-833-2438 (Utilizes Telecommunication Devices for the Deaf/Text Telephones, TDD/TTY).

The attached 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 card and returning it to us in the postage paid envelope.

If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

In order to assure your full protection under the emission warranty provisions, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Failure to reprogram the PCM may cause your vehicle to fail a state or local emission inspection or I/M smog check test.

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof Of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

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

Chevrolet Motor Division

General Motors Corporation

Enclosure