Customer Satisfaction 99074 - Accel Cable Detaches from Throttle Body Cam Cable

General Motors has decided that certain 2000 Chevrolet Malibu and Lumina; Pontiac Grand Prix; and Buick Century model vehicles equipped with 3.1L (RPO LG8) engine may exhibit a condition in which the throttle cable detaches from the throttle body because of an oversized cable ball retention feature on the throttle cam. If this occurs, the throttle valve will return to and remain at the idle position, even if the driver depresses the accelerator pedal, making the vehicle undriveable.

To prevent the possibility of this condition occurring, dealers are to replace the throttle body assembly.

Involved are certain 2000 Chevrolet Malibu and Lumina; Pontiac Grand Prix; and Buick Century model vehicles equipped with 3.1L (RPO LG8) engine and built within the following VIN breakpoints:

Important: 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 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: Due to the small number of vehicles involved (661), dealers are encouraged not to order campaign parts for use as shelf stock.

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).

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.

Tools Required

J 24460-01 Cooling System Pressure Tester

Throttle Body Removal Procedure

1. Prep the vehicle.
2. When the engine is cool, turn the cooling system pressure cap counterclockwise about one turn slowly and then stop. Wait until any residual pressure is relieved from the cooling system. Residual pressure will be indicated by a hissing sound. After the hissing stops, rotate the cooling system pressure cap counterclockwise until the cap can be removed.




Important: On the Chevrolet Malibu, it will be necessary to remove the air close-out panel, between the radiator core support and the engine cradle.

3. Drain the cooling system. Using 1/4 inch drive ratchet and extension, loosen the radiator drain valve, located on the driver's side of the vehicle. Drain the coolant into an appropriate clean storage receptacle for installation later.



4. Disconnect the cruise control cable (3) from the accelerator control cable bracket (2) by gently pressing on the cable retaining tab (6) and sliding the cable from the bracket.
5. Remove the cruise control cable eyelet (9) from the throttle body cam (8).
6. Remove the accelerator cable (4) from the accelerator control cable bracket (2) by gently pressing on the cable retaining tab (5) and sliding the cable from the bracket.
7. Remove the accelerator cable from the throttle body cam by lifting the cable out of the cable guide channel (10), and then remove the cable ball (7) from the throttle cam socket (1).

Malibu





Grand Prix





Important: On the Grand Prix, the air cleaner box assembly uses spring clamps in place of screws (1).

8. Remove the air intake tube and the upper air cleaner box by loosening the clamp (2) and removing the screws (1) from the air cleaner box assembly.
9. Disconnect the mass air flow electrical connector (5) and the intake air temperature sensor electrical connector (4).
10. Remove the crankcase fresh air vent tube from the air inlet (3).
11. Remove the air intake tube and the upper air cleaner box assembly from the vehicle.



12. Disconnect the idle air control (IAC) valve electrical connector, located on the throttle body.



13. Disconnect the throttle position (TP) sensor electrical connector.



14. Remove the accelerator control cable bracket by removing the bolts (1) and the nut (2). Position the bracket over the intake manifold.



15. Loosen the throttle body coolant bypass hose clamps (7) from the thermostat bypass pipe fittings.
16. Remove the thermostat bypass pipe nut (6) from the throttle body.
17. Loosen the thermostat bypass pipe hose clamp (2) from the intake manifold. Remove the hose from the fitting.
18. Remove the engine oil dipstick indicator (4).
19. Disengage the left bank spark plug wire retainer (5) from the intake manifold and the thermostat bypass pipe (3).
20. Remove the left bank spark plug wires from the spark plugs and position them over the intake manifold.
21. Remove the thermostat bypass pipe retaining bolt (1) from the water pump housing.
22. If the vehicle is equipped with secondary air injection (SAI), complete the following steps. Otherwise, skip to Step 23.




22.1.

For Malibu vehicles, remove the vacuum lines from the SAI solenoid (2) and the air switching valve assembly (3).

22.2.

For Malibu vehicles, remove the retaining nut (1) from the SAI air switching valve bracket assembly.

22.3.

Remove the SAI solenoid wiring connector (4) and the solenoid assembly (2).





22.1.

For Grand Prix vehicles, separate the air pump supply hose (5) from the air switching valve (1) and the SAI pump supply hose (4).

22.2.

Remove the SAI pipe retaining bolt (3).

22.3.

Gently slide the SAI pipe tube towards the driver's side of the vehicle, approximately 2 to 3 inches away from the throttle body.

Important: It is NOT necessary to remove callout #2 on the illustration to complete this process.

23. Gently lift upwards on the thermostat bypass pipe to disengage it from the water pump housing. Slide the tube toward the driver's side of the vehicle approximately one inch, while removing the throttle body coolant bypass hoses from the heater outlet tube.



24. Remove the throttle body attachment bolt (3) and the stud (2).
25. Remove the throttle body assembly from the intake manifold.
26. Remove the throttle body gasket (1).

Throttle Body Installation Procedure

Notice: Do not use solvent of any type when cleaning the gasket surface on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and the throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.




1. Clean the gasket surface on the intake manifold.
2. Remove the throttle body coolant bypass hoses from the OLD throttle body and install them on the NEW throttle body.
3. Install the new throttle body gasket (1).
4. Install the NEW throttle body assembly.

Tighten
Tighten the throttle body attachment bolt (3) and the stud (2) to 25 N·m (18 lb ft).




5. Position the thermostat bypass pipe back to its original position, while installing the throttle body coolant bypass hoses (7) onto the heater outlet tube.
6. Install the throttle body coolant bypass hose clamps onto the hose fittings.
7. Position the thermostat bypass pipe into the water pump outlet housing. Install the thermostat bypass retaining bolt (1).

Tighten
Tighten the thermostat bypass pipe retaining bolt to 11 N·m (98 lb in).

8. Install the thermostat bypass pipe retaining nut (6) onto the throttle body stud.

Tighten
Tighten the nut to 25 N·m (18 lb ft).

9. Install the thermostat bypass pipe hose and the clamp (2).
10. Install the engine oil dipstick (4).
11. Install the left bank spark plug wires onto the respective spark plugs. Install the wire harness retainer clips onto the thermostat bypass tube (3) and the intake manifold (5).
12. If the vehicle is equipped with secondary air injection (SAI), complete the following. Otherwise, skip to Step 13.




12.1.

For Malibu vehicles, install the SAI solenoid and the air switching valve bracket retaining nut (1).

Tighten
Tighten the nut to 10 N·m (89 lb in).

12.2.

For Malibu vehicles, install the vacuum lines to the SAI solenoid (2) and the air switching valve (3).

12.3.

For Malibu vehicles, install the SAI solenoid electrical connector (4).





12.1.

For Grand Prix vehicles, move the SAI pipe back to its original position.

12.2.

For Grand Prix vehicles, install the air supply hose (5) onto the air switching valve (1) and the SAI pump supply hose (4).

12.3.

For Grand Prix vehicles, install the SAI pipe retaining bolt (3).

Tighten
Tighten the bolt to 10 N·m (89 lb in).




13. Install the accelerator control cable bracket using the bolts (1) and the nut (2).

Tighten
Tighten the bolts and the nut to 10 N·m (89 lb in).




14. Install the idle air control (IAC) valve electrical connector.



15. Install the throttle position (TP) sensor electrical connector.

Malibu





Grand Prix




16. Install the air intake tube and the upper air cleaner box. Install the air cleaner box screws (1) and tighten the air intake tube clamp (2).

Important: On the Grand Prix, the air cleaner box uses spring clamps in place of screws (1).

17. Install the fresh air vent tube (3).
18. Install the mass air flow (MAF) electrical connector (5) and the intake air temperature (IAT) electrical connector (4).



19. Install the accelerator cable into the throttle body cam by installing the cable ball (7) into the throttle body cam socket (1). Insert the cable into the cable guide channel (10). Gently tug on the accelerator cable to ensure that the cable ball and the core wire are seated into the cam retention features.
20. Install the accelerator cable (4) into the accelerator control cable bracket (2). Ensure that the retaining tab (5) has been properly seated into the detent on the bracket.
21. Install the cruise control cable eyelet (9) into the throttle body cam (8).
22. Install the cruise control cable (3) into the accelerator cable control bracket (2). Ensure that the retaining tab on the cruise cable (6) has been properly seated into the detent on the bracket.

Important: The throttle should operate freely without binding between full closed and wide-open throttle. Test for proper throttle opening and closing positions by operating the accelerator pedal. Also, inspect for proper carpet fit under the accelerator pedal.

Important: On the Chevrolet Malibu, it will be necessary to install the air close-out panel between the radiator core support and the engine cradle.

23. Using a 1/4 inch drive ratchet and extension, tighten the radiator drain valve, located on the driver's side of the vehicle.



24. Open the air bleed on the thermostat bypass pipe (1).
25. Refill the cooling system using saved engine coolant. Fill the system until the coolant flows from the air bleed, located on the thermostat bypass pipe (1).
26. Close the air bleed on the thermostat bypass pipe (1).

Tighten
Tighten the air bleed to 10 N·m (89 lb in).




27. Install the cooling system pressure tester J 24460-01 (and adapter J42-401 on the Malibu). Pressurize the cooling system for approximately two to three minutes and inspect for leaks at the throttle body and the thermostat bypass tube connections.
28. Remove the cooling system pressure tester J 24460-01.
29. Install the radiator pressure cap.
30. Install the GM 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 pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

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

Submit a Product Campaign Claim with the information indicated below.

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.

General Motors has decided that certain 2000 Chevrolet Malibu and Lumina; Pontiac Grand Prix; and Buick Century model vehicles equipped with 3.1L engine may exhibit a condition that could allow the throttle cable to detach from the throttle body. If this happens, the throttle valve will return to the idle position and remain there even if the driver depresses the accelerator pedal, making the vehicle undriveable.

To prevent the possibility of this condition occurring, your dealer will replace the throttle body 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.

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 number listed below:

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.

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.

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