VARIOUS DRIVEABILTY CONDITIONS (REPAIR OVERSIZED TERMINALS)
SUBJECT: VARIOUS DRIVEABILITY CONDITIONS
MODEL and YEAR: 1992 CAPRICE, CORSICA AND BERETTA 1992 C/K TRUCK AND G, L/M VANS
ENGINE APPLICATIONS: SUBJECT: 2.3L (LG0), 3.1L (LH0), Micro-Pack Terminals causing 4.3L (LB4, Driveability Complaints 5.0L (L03), 5.7L (L05)
ENGINE VIN (Models): VEHICLE/TRUCK APPLICATIONS: Car A,E,L,TZ,7 1992 Model Year B,L, Cars Truck H,K,WZ 1992 Model Year C,K Trucks 1992 Model Year G,L,M Vans
CONDITION:
---------- Some owners of the vehicles listed below may experience various driveability conditions such as reduced fuel economy, SES light, runs rough, misses, etc. (specific concerns are described in the following paragraphs). If diagnosis indicates a need to replace any control system components (example, ECM or sensors), check suspect connector terminals and repair if necessary prior to replacing the control system component.
CAUSE:
------ The condition may be a result of intermittent or open circuits caused by insufficient contact between the ECM harness female terminal and the mating ECM male pin. Some of the 12089649 micro-pack 100 series female terminals (formerly P/N 12020757) could have an oversized contact area condition. NOTE: Either terminal may be used in repair.
VIN BREAKPOINTS:
Suspect vehicle VIN breakpoints for PASSENGER CARS follow:
Willow Run
Beginning VIN Ending VIN ------------- ----------- 1G1BN53E1NW135953 1G1BN53E6NW138380 1G1BL83E5NW135087 1G1BL83E5NW138796 1G1BL53Z9NW134624 1G1BL53Z5NW138153
Arlington
1G1BL5373NR133692 1G1BL5374NR143714
Wilmington** ------------ 1G1L*#3T@NY239772 1G1L*#3T@NY254066 1G1L*#3T@NY700980 1G1L*#3T@NY701089 -------- * Any one of T, V, W carline series codes ** Multiple codes possible for certain positions on VIN # Either 1 or 5 - 2-door or 4-door code @ is a check digit; range from 0 - 9 or "X"
Suspect vehicle VIN breakpoints for TRUCKS follow:
Oshawa
Beginning VIN Ending VIN -------------- ----------- 2GCEC19Z0N1213269 2GCEC19K2NI217746
Pontiac East
1GCDC14Z5NE182893 1GBJC34K7NE187129 1GCEK14Z3NE190742 1GBGK24K7NE191513
Fort Wayne
1GCDC14ZONZ188089 1GCEK14K6NZ192898
Baltimore
1GNEL19WGNB178637 1GNDM19W5NB194028
Scarborough
2GBEG25K9N4132342 2GCEG25Z9N4147935
Lordstown
1GNEG25K8N7124997 1GCCG15H8N7132502
SYMPTOMS (Passenger Car)
Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s) ------ ------- ---------- ---------- ----------- 1992 Caprice/Custom Cruiser/Roadmaster --------------------------------------- All All 419 A5/BRN/WHT 1. SES light will not SES light driver illuminate
All All 467 D16/DkBLU 1. Detonation Injector 1 2. No power 3. Hard start All All 468 D14/DkGRN 4. Rough idle Injector 2 5. SES light "on" (if circuit 419 okay) 6. Code 43 and/or 44 stored 7. No start if both circuits open 8. Miss 9. Hesitates 10. Surge 11. Quit 12. Intermittent circuit may or may not set codes ------------------------------------------------------------------------------ 1992 Riviera ------------- 3800(L27) All 630 A12/BLK 1. SES light "on" VIN L Cam sensor 2. Code 41 stored 3. Stalls 4. Runs rough ------------------------------------------------------------------------------ 1992 Corsica/Beretta -------------------- 3.1 L (LH0) All 410 E16/YEL 1. SES light "on" VIN T Cool. temp. 2. Code 15 stored sensor 3. Runs rough 4. Hard start 5. Floods (except in very cold ambient) 6. Reduced fuel economy 7. Exhaust odor 8. No power 9. Cooling fan always on under 35 MPH 10. Intermittent circuit may or may not set code 15 11. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------ 1992 Grand Am/Achieva/Skylark ----------------------------- 2.3L (LD2) All 888 C15/DkBLU 1. SES light "on" VIN D Injectors 2/3 C13/DkBLU 2. Codes 44 and/or 65 (L40) All stored 3. No start VIN 3 4. Stalls (LG0) All 5. Hard start VIN A 6. Detonation 7. No power 8. Intermittent circuit may or may not set codes ------------------------------------------------------------------------------ 3300 (LG7) All 639 A6/PNK/BLK 1. Stalls VIN N Ignition 2. Stumbles 3. SES light flashing 4. No codes stored 5. No SES light 6. No start 7. No ALDL data 8. Intermittent circuit will cause erratic Tech 1 readings
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SYMPTOMS (Trucks)
Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s) ------- ------- ---------- ---------- ---------- 1992 C/K Trucks (Regular or Extended Cab) GVW less than 7200 lbs. ----------------------------------------------------------------- 5.0L (L03) MG5/MT8 413 D6/TAN 1. SES light "on" 5.7L (L05) Man tran O2 sensor 2. Code 13 stored ground 3. Stalling 4. Detonation 5. Surge 6. Hesitates 7. Engine runs rough 1992 C/K Trucks(Regular or Extended Cab) All Series 8. Intermittent circuit --------------------------------------------------- may or may not 5.0L (L03) MD8-4L60 413 D6/TAN set code 13 trans O2 sensor 9. Erratic engine ground operation 10. Intermittent circuit will cause erratic Tech 1 readings
1992 C/K Trucks (Regular or Extended Cab) 10 & 20 Series -------------------------------------------------------- 5.7L (L05) MD8-4L60 413 D6/TAN trans O2 sensor ground
1992 C/K Trucks (Regular, Extended or Crew Cab) 8600 GVW & over --------------------------------------------------------------- 5.7L (L05) MT8 413 D6/TAN Man tran O2 sensor ground
1992 M/L Van ------------- 4.3L (L35) All 120 B2/GRY 1. SES light "on" Fuel pump 2. Code 54 stored signal 3. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------ 4.3L (L35) All *450 A12/BLK 1. Erratic engine Ground operation 2. Stalling 3. Surge 4. Flickering SES light *The terminals for system ground 5. No codes stored circuits 450 and 551 must both be 6. No start replaced on M/L vans if any one of 7. Quit the ground terminals is found faulty. 8. Hesitates Use established replacement procedures. 9. Poor fuel economy 10. Hard start 11. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------
1992 G Van
5.0L (L03) MD8-4L60 *450 D1/BLK/WHT 1. Poor fuel economy 5.7L (L05) Trans System 2. Erratic engine ground operation 3. Stalls 4. No start 5.7L (L05) MT1-4L80E *551 C3/Tan/WHT 5. Quit JA4 *450 C2/BLK/WHT 6. Hard start 92C (SEO) 7. Flickering SES light 8. No codes stored *The terminals for system ground 9. Hesitates circuits 450 and 551 must both be 10. Surge replaced on G vans if any one of 11. Intermittent circuit the ground terminals is found faulty. will cause erratic Use established replacement procedures. Tech 1 readings ------------------------------------------------------------------------------
5.0L (L03) MD8-4L60 441 C5/LtBLU/WHT 1. Stalls 5.7L (L05) JA4 IAC "A" Hi 2. Low or high idle 3. Intermittent circuit could cause erratic idle 5.7L (L05) MT1-4L80E 441 JA4 IAC "A" Hi ------------------------------------------------------------------------------
5.0L (L03) MD8-4L60 437 A10/BRN 1. SES light "on" 5.7L (L05) JA4 VSS 2. Code 24 stored 3. Unstable idle 4. Intermittent circuit may or may not set code 24 5. No TCC 6. Poor fuel economy 7. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------
5.7L (L05) MT1-4L80E 437 B11/BRN 1. SES light "on" JA4 VSS 2. Code 24 stored 3. No shift beyond 2nd 4. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------
5.7L (L05) MT1-4L80E 496 D5/DkBLU 1. SES light "on" JA4 ESC (knock) 2. Code 43 stored signal 3. Spark knock 4. Intermittent circuit may or may not set code 43 ------------------------------------------------------------------------------
5.7L (L05) MD8 467 D16/BLU 1. Detonation 4L60 Injector 1 2. No power 3. Hard start 4. Rough idle 5. SES light "on" 6. Code 43 and/or 44 stored 7. Miss 8. Hesitates 9. Surge 10. Quit 11. Intermittent circuit may or may not set codes ------------------------------------------------------------------------------
5.7L (L05) MT1-4L80E 435 A11/GRY 1. SES light "on" JA4 EVRV(EGR) 2. Code 32 stored control 3. Rough idle 4. Poor fuel economy 5. Hesitates 6. Stall at idle 7. Intermittent circuit may or may not set code 32 ------------------------------------------------------------------------------
5.7L (L05) MT1-4L80E 420 A12/PPL 1. No TCC JA4 Brake signal 2. No shift to 4th gear 3. Poor fuel economy 4. Intermittent circuit will cause erratic Tech 1 readings ------------------------------------------------------------------------------
4.3L (LB4) MT8-4L60 452 A11/BLK 1. SES light "on" JA4 CTS & TPS 2. Codes 15 and/or 21 sensor and/or 45 stored ground 3. High idle 4. Poor fuel economy 5. Engine runs rich 6. Hard start 7. Hesitates 8. Surges 9. Stall 10. No power 11. Exhaust odor 12. Intermittent circuit may or may not set codes 13. Intermittent circuit will cause erratic Tech 1 readings
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CORRECTION:
----------- 1. To check for an oversize terminal, use a #62* drill bit (.038 inches, .965 mm) and place a mark 1/2 inch up from the bottom of the shank of the drill bit. Place a flag made from tape at the mark on the drill (see Figure 1).
2. Remove connector from ECM and hold connector vertically up.
3. Place shank of #62* drill bit (.038 inches, .965 mm) in connector cavity of suspect terminal. Do not push on drill (see Figure 2).
4. Repair any terminal allowing drill bit to fall unassisted to the flag on drill bit. Any terminals having resistance or drag or not allowing drill to enter terminal are okay and do not need repair. Repair any oversized terminal as described in steps 5 through 8.
5. Remove the TPA (terminal position assurance) from the connector.
6. Remove the terminal from the connector using terminal removal tool GM 12031876-1 (Kent-Moore Tool No. J 38125-A).
7. With a pair of small needle nose pliers, resize the contact area of the terminal as shown in Figure 3.
8. To verify the terminal has been adequately sized, insert a #63* drill bit (.037 inches, .940 mm) into the contact area as shown in Figure 4. If resistance can be felt against the bit in the resized area, resizing is complete. If no resistance is felt, repeat steps 7 and 8.
9. Raise the terminal lock tang (Figure 4) so the terminal can be properly held in the connector.
10. Reinsert the terminal into the proper connector cavity.
11. Reinsert the TPA into the connector.
12. If the terminal becomes severely damaged by using this method, replace the terminal using established terminal replacement procedures.
13. Reinstall harness to ECM and perform any required relearn procedure prior to continuing diagnosis.
* NOTICE: Measure drill to ensure drill is of proper diameter. A larger sized drill will damage a good terminal.
WARRANTY INFORMATION:
Use applicable labor operation and time allowances.
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.
