Product Emission 99088A - Check Eng Light On (Install Protective PCM Shield)

This bulletin is being revised to correct parts and claim information. Please discard Product Campaign Bulletin Number 99088, dated February, 2000.

General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1995-96 Chevrolet Cavalier and Pontiac Sunfire (J car) model vehicles. These vehicles may exhibit symptoms resulting in the illumination of the Check Engine light or the engine runs rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. This may be due to moisture entering the Powertrain Control Module (PCM), as a result of corrosion.

To correct this condition, dealers are to clean and/or replace the Powertrain Control Module (PCM), then seal the PCM in a protective shield/cover assembly.

Involved are certain 1995-96 Chevrolet Cavalier and Pontiac Sunfire (J car) model vehicles built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry 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 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 campaign.

Important: CORES ARE TO BE RETURNED VIA THE NORMAL CORE RETURN PROCESS. PCM (ECM) CORES SHOULD NOT BE SENT TO THE PDCs. BULLETIN IB#98-320 AUTHORIZES THE RETURN OF "CORRODED/WATER-DAMAGED ECMs...FOR CORE RETURN CREDIT" ON CAMPAIGN PCM PART NUMBERS 16192232, 16196285 AND 16215830.

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.

Important: Dealers are encouraged to order covers, shields and retainer pins in the geographical location of vehicles involved. However, due to limited initial parts availability of PCMs, dealers are encouraged not to order PCMs for use as shelf stock. PCMs should only be ordered when inspection determines that it is necessary to replace the PCM.

1. Disconnect the negative battery cable.
2. Remove the right-hand engine splash shield (in front of the right tire assembly).
3. Remove the horn attachment bolt. Disconnect the wire and remove the horn.
4. Remove the PCM retainer attachment bolts (2). Slide the PCM and the retainer from the PCM bracket. Remove the retainer from the PCM.
5. Disconnect the PCM from the harness.
6. With the PCM harness disconnected, inspect the green weatherpack seal to ensure that the seal is intact and sealing properly to the wires and the body of the connectors.
7. Visually inspect the PCM for signs of corrosion or corrosion debris.

•	If no corrosion is visually present, proceed to Step 10.

•	If the PCM case has light surface corrosion, which could be cleaned using a Scotch Brite® or equivalent pad, especially where the two case halves seal and where the connectors seal to the case, proceed to Step 9.

•	If the PCM case has significant surface corrosion, especially where the two case halves seal and where the connectors seal to the case, proceed to Step 8.

8. Replace the PCM.

•	For 1995 vehicles: Transfer the EPROM (memcal/ESC module) from the original PCM to the replacement PCM. Proceed to Step 10.

•	For 1995 vehicles with LD2/MN4 or for 1996 vehicles: Transfer the knock sensor (ESC) module from the original PCM to the replacement PCM. Proceed to Step 10.

9. If the original PCM is to be placed in the vehicle, then the exterior surface must be thoroughly cleaned with a 3M Scotch Brite® or equivalent pad. Do not open the case and clean any internal surfaces. Also, the inside of the sealing shrouds for the connector must be CLEAN. Inspect for any obvious signs of damage to the sealing shroud such as cracks, pitting from corrosion, or corrosion debris that cannot be removed. Do not wire brush or file the sealing surface smooth. If any such conditions exist, the PCM must be replaced. Proceed to Step 10.

Important: The harness assembly will not seal if the sealing shroud of the PCM is damaged.

Important: The areas to be sealed must be thoroughly cleaned before applying the RTV Silicone Sealer. Failure to properly clean and prepare the surfaces to be sealed may result in an ineffective seal, which could allow moisture to enter the PCM case.




10. The following procedure applies to original or new PCMs

Using a shop cloth, spray "brake clean," P/N 12377981 or the equivalent, onto the shop cloth (do not use Carb Cleaner, as it will leave an oil residue). Clean the areas to be sealed on the PCM (do not spray directly onto the PCM). Apply RTV silicone sealer, P/N 12345739 or the equivalent, to the entire perimeter of the PCM case, the screws and any areas where water may enter the case of the PCM. Apply the RTV silicone sealer to the KS (knock sensor) module or EPROM access cover and allow to setup before reinstalling in the vehicle.

11. Apply lubricant, P/N 12377900, to the weatherpack seal surface area of the connectors and reconnect the harness to the PCM.



12. Reinstall the plastic retainer to the PCM.
13. Install the PCM cover, P/N 22623903, over the PCM with the "F" facing outward.
14. Install the PCM into the vehicle bracket.



15. Install the PCM shield assembly, P/N 22623904, to the vehicle. Drape the shield over the PCM bracket. Remove the evap hose clip fastener and reinstall through the shield. Push the square cut over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through the shield.
16. Install the push-in retainer, P/N 10121502, through the lower front hole of the PCM shield and then through the side hole of the PCM cover.



17. Reprogram the new PCM (1995 LD2/MN4 and 1996 vehicles).
18. Install the Campaign Identification Label.

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign 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 Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Offices.

Submit a Product Campaign Claim with the information indicated below.

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

It is not expected that there would be owner reimbursement associated with this campaign since the affected component is covered by the 8 year/80,000 miles emission control systems warranty.

If an owner requests a reimbursement for previously completed repairs, this must be considered on a case by case basis as follows:

Customer requests for reimbursement of previously paid repairs to correct this condition are to be submitted prior to or by March 31, 2002 (this time limitation may be longer depending upon the law in your state/province/country).

Consideration for reimbursement will be allowed only if genuine General Motors parts were used. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM service policies and procedures manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Customers, in the fifteen high corrosion states, will be notified of this campaign on their vehicles by General Motors (see copy of 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 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 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.

Dear <Division(s)> Customer:

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

General Motors has decided that certain 1995 and 1996 Chevrolet Cavalier and Pontiac Sunfire model vehicles may exhibit symptoms resulting in the illumination of the Check Engine light or the engine runs rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted. This may be due to moisture entering the Powertrain Control Module (PCM), as a result of corrosion.

To correct this condition, your dealer will inspect, clean and/or replace the Powertrain Control Module (PCM), then seal the PCM in a protective shield/cover assembly. This service will be performed for you at no charge .

Please contact your <Division> 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.

Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed below:

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 postage paid reply card and returning it to us.

Your dealer will 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 ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, 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. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

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

Enclosure