ENGINE CRANK - NO START CONDITION

SUBJECT: ENGINE CRANK - NO START CONDITION (REPAIR OPEN IN CKT 480 WITH WIRE SPLICE)

MODELS: 1995 CHEVROLET CAVALIER 1995 PONTIAC SUNFIRE

CONDITION:

SOME OWNERS MAY COMMENT ON AN ENGINE NO START CONDITION. TECHNICIANS WILL FIND NO SERIAL DATA.

CAUSE:

CKT 480 (ORANGE) BETWEEN POWERTRAIN CONTROL MODULE (PCM) CONNECTOR C2 TERMINAL 11 AND PCM FUSE OF THE ENGINE COMPARTMENT FUSE/RELAY CENTER MAY BE FOUND OPEN OR WITH HIGH RESISTANCE.

CORRECTION:

1. RAISE VEHICLE.

2. REMOVE THE FOUR CONDUIT CLIPS ON THE LOWER RADIATOR TIE BAR.

3. PULL THE TAPED BUNDLE OF WIRES OUT OF THE CONDUIT.

4. WITH THE WIRES OUT OF THE CONDUIT, CUT OUT A PORTION OF CONDUIT STARTING 50MM INBOARD OF THE LEFT HAND WHEEL SPEED SENSOR BRANCH (SEE FIGURE 1, ITEM 1) TO THE MIDDLE OF THE TIE BAR, APPROXIMATELY 350MM LONG.

5. REMOVE THE TAPE FROM THE HARNESS STARTING AT THE LEFT FRONT WHEEL SPEED SENSOR BREAKOUT FOR AT LEAST 200MM INBOARD.

6. THERE SHOULD BE VISIBLE DAMAGE TO THE INSULATION OF CKT 480 (ORANGE) AND POSSIBLE CORROSION APPROXIMATELY 100MM INBOARD OF THE BREAKOUT FOR THE LEFT FRONT WHEEL SPEED SENSOR (SEE FIGURE 1, ITEM 2). IMPORTANT: EVEN A VERY SMALL PIN HOLE IN THE INSULATION WILL ALLOW THIS CIRCUIT TO CORRODE OPEN.

7. REMOVE THE SECTION OF WIRE ABOUT 50MM TO EITHER SIDE OF THE DAMAGE/OPEN. STRIP WIRE AND FOLD STRIPPED PORTION IN HALF TO DOUBLE THICKNESS WHILE USING THE HEATED SEALED WIRE SPLICE SLEEVE, P/N 12089189. THE REPAIR MUST BE SEALED TO PREVENT A RETURN OF THE CONDITION. REFER TO SECTION 8A-4 IN THE SERVICE MANUAL FOR WIRE REPAIRS.

8. AFTER REPAIRS ARE COMPLETE, REPLACE THE CONDUIT WITH SPLIT FACING DOWN TO ALLOW FOR WATER DRAIN (SEE FIGURE 1, ITEM 3). TAPE THE CUT PORTION OF THE CONDUIT TO THE EXISTING CONDUIT.

PARTS INFORMATION:

PART NUMBER DESCRIPTION =========== ===========

12089189 HEATED SEALED WIRE SPLICE (SALMON - 20/18 GAUGE)

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR INFORMATION NUMBER: N6270 USE PUBLISHED LABOR OPERATION TIME.

FIGURES: 1 ATTACHMENTS: 0

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.

COPYRIGHT 1995 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.