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Makes 🢒 Chevrolet 🢒 2004 🢒 Colorado Pickup - 4WD 🢒 Bulletins 🢒 Engine Control Concern Due to Intermittent PCM Connection Loss - kw 2.2 2.8 3.5 L52 L61 LK5 cold communication connector control cruise DTC ECT erratic EVAP fuel gauge generator H02S hot idle ignition

Engine Control Concern Due to Intermittent PCM Connection Loss - kw 2.2 2.8 3.5 L52 L61 LK5 cold communication connector control cruise DTC ECT erratic EVAP fuel gauge generator H02S hot idle ignition

Subject:Engine Control Concerns due to Intermittent PCM Connection Loss

Models:.


The following diagnosis might be helpful if the vehicle exhibits the described symptoms in the PI.

Condition/Concern:

Some 2004 Chevrolet Colorado and GMC Canyons (Last 8 of VIN Below 48103559) and some 2004 Chevrolet Malibus (No VIN Breakpoint - 2.2L Engine Only - New Body Style Only) may experience various, intermittent engine control concerns. This may be due to loose female terminal tension at any of the PCM connectors. The loose tension may be a result of an irregular, male PCM terminal. An irregular male terminal may damage a female terminal when the PCM connector is latched to the PCM. This, combined with normal operating vibrations, may cause an intermittent PCM connection to occur.

Recommendation/Instructions:

If the SI diagnostics do not isolate a concern, the following information may help:

  1. Inspect the related, female PCM connector terminal (s) for loose tension by using male test probe J-35616-64A.
  2. If loose terminal tension is found, inspect the related male PCM terminal (s) for excessive (tight) drag by using female service terminal # 15359541. If excessive drag is present, the male PCM terminal may have an irregular profile. Also, inspect the suspect male PCM terminal (s) with a magnifying glass and proper lighting. If any concerns are noticed when compared with other non-suspect terminals,replace the PCM. If no concerns are noted, do not replace the PCM.
  3. After inspecting or replacing the PCM, replace the female PCM connector terminal (s) that had loose terminal tension with part number 15359541, which is in Tray 4 of the Delphi Terminal Kit. To do this, follow the "Repairing Connector Terminals" procedure that is published in SI. Use terminal release tool 15381651-2 to release the terminal from the PCM connector and use crimp tool J38125-64 to install the new female terminal.

Additional Notes:

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If necessary, use male test probe J35616-64A in combination with female test tool J35616-65A to determine how proper terminal tension should feel.

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At this time, all of the special tools above are available by calling SPX Kent-Moore at 1-800-468-6657. The terminals are also available through SPX Kent-Moore in packages of 10 and the part number needed when ordering them is 15359541-PKG.

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These terminal are very small and delicate terminals that will only have a very small amount of resistance to the J-Tool Probe.

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Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(04 Chevrolet Colorado S1 T1) and (04 Chevrolet Malibu with the 2.2L L61 Engine ZB) and (04 GMC Canyon S1 T1)

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