CAMPAIGN: INCORRECT EMISSIONS SYSTEM OUTSIDE OF CALIFORNIA

Model and Year: 1989 CHEVROLET GEO METRO AND METRO LSi

General Motors has determined that a small number of 1989 Chevrolet Geo Metro and Metro LSi model vehicles were incorrectly distributed. Some vehicles equipped with California emissions systems were distributed in states other than California. This condition could cause an involved vehicle to fail state mandated emissions tests.

To correct this condition, dealers will inspect the emission control system on your vehicle to determine if it has the correct system. If not, the correct system will be installed.

VEHICLES INVOLVED

Involved are certain 1989 Chevrolet Geo Metro and Metro LSi model vehicles produced within the following VIN breakpoints:

MODEL/YEAR PLANT FROM THROUGH

1989 Metro & Kosai KK702357 KK766478 Metro LSi

NOTICE: A total of 231 units comprising 45 Metro model (VIN I.D. MS) and 186 Metro LSi (VIN I.D. MR) with California Emissions systems were distributed outside the state of California.

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner 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. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

NOTICE: Due to the small number of vehicles involved, and to insure parts availability upon owner requests for this vehicle correction, dealers are encouraged to order parts based on their attached involved vehicle listings. Quantity/ Part Number Description Vehicle ------------ ---------------------- ----------- (Metro Parts - VIN I.D. MS)

30002868 ECM 1 96062341 Emission Control Label 1

(Metro LSi Parts VIN I.D. MR)

30002871 ECM (Automatic Transmission) 1 30002870 ECM (Manual Transmission) 1 96060059 Intake Manifold 1 96060341 Distributor 1 00343350 Vacuum Plug 1 09438381 Vacuum Hose - Bulk 280 mm Length " " " " " 380 mm Length 96055329 Clamp, Vacuum Hose 96056807 Clip, PCV and Vacuum Hose 96062340 Emission Control Label 96060060 Gasket, Intake Manifold 96060074 Gasket, TBI to Intake Manifold

SERVICE PROCEDURE

NOTICE: Many of the the procedures in this bulletin may also be found in the 1989 Geo Metro Service Manual sections 6 through 6E2. If further clarification or detail is required, these sections may be helpful.

1. Determine which emission system is installed on vehicle by inspecting the vehicle emission control information label on underside of the engine compartment hood panel.

a. If information label indicates California emission system is installed and the state in which the vehicle is licensed/registered IS CALIFORNIA, no correction action is required. Install Campaign Identification Label and return vehicle to customer or to dealer stock.

b. If information label indicates California emission system is installed and the state in which the vehicle is licensed/registered IS NOT CALIFORNIA, corrective action is required to convert emission system from California to Federal. Follow procedure appropriate to vehicle model designation shown in VIN positions 4 and 5.

Vehicle Model Designations

MS = Metro MR = Metro LSi

For MR models only:

2. Relieve fuel pressure.

a. Place gearshift lever in "Neutral" (Manual Transmission) or "Park" (Automatic Transmission), set parking brake and block front (drive) wheels.

b. Remove fuel pump relay from underhood relay center located in front of the drivers side strut tower. Disconnect relay electrical connector.

c. Start engine and allow to stall.

d. Remove fuel filler cap.

e. Crank engine an additional 30 seconds to remove any residue fuel in pressure line.

f. Disconnect negative battery cable.

3. Remove throttle body.

a. Remove air cleaner assembly.

b. Drain engine coolant.

c. Disconnect the following electrical connectors:

- Throttle switch (manual transmission) or throttle position sensor (automatic transmission).

- Fuel injector electrical connector.

- Coolant temperature sensor.

d. Disconnect the following hoses at the throttle body:

- Fuel feed and return hoses (2).

NOTICE: Use a shop towel to catch any fuel left in the fuel lines during removal of fuel lines.

- Engine coolant hoses (2).

- Various vacuum hoses.

e. Disconnect accelerator cable.

f. Disconnect throttle body attaching fasteners (4).

g. Remove throttle body and old gasket.

4. Remove intake manifold.

a. Disconnect the following electrical connectors at the intake manifold:

- EGR valve vacuum switching valve solenoid.

- ISC solenoid valve.

- Instrument panel temperature gauge.

b. Disconnect the following vacuum hoses at the intake manifold:

- Canister purge hoses (2).

- PCV valve hose.

- Brake booster hose.

c. Disconnect engine coolant hoses (2).

d. Disconnect ground wires (3).

e. Remove EGR valve VSV bracket assembly.

f. Remove intake manifold fasteners.

g. Remove intake manifold.

5. Remove distributor:

NOTICE: Before removing distributor, #1 piston should be set at top dead center (TDC) and timing marks should indicate zero (0) degrees on front cover.

a. Disconnect three (3) spark plug wires at distributor cap.

b. Disconnect coil wire at distributor.

c. Disconnect two (2) vacuum hoses at distributor.

d. Disconnect electrical connector.

e. Remove two (2) fasteners holding distributor to the cylinder head.

f. Remove distributor.

6. Clean cylinder head of any remaining gasket material left by the intake manifold.

7. Transfer components from old intake manifold to new intake manifold.

a. Remove the following from the old intake manifold:

- Throttle body attaching studs (2).

- Bimetal vacuum switch valve for canister.

- Instrument panel temperature gauge sensor.

- Vacuum fuel vapor filter.

- PCV valve assembly.

- ISC solenoid valve and bracket assembly.

b. Install the following on the new intake manifold:

- Throttle body attaching studs (2).

- Bimetal vacuum switch valve for canister using a thread sealant.

- Instrument panel temperature gauge sensor using a thread sealant.

- Vacuum fuel vapor filter using a thread sealant.

- PCV valve assembly using two (2) fasteners previously removed.

- ISC solenoid valve and bracket assembly.

8. Install new intake manifold.

a. Install new intake manifold gasket to cylinder head.

b. Install intake manifold to cylinder head.

c. Install six (6) fasteners to intake manifold. Tighten the fasteners from the center of the intake manifold out to 23 Nm (17 lb. ft.).

d. Connect canister purge hoses (2).

e. Connect engine coolant hoses (2).

f. Connect PCV valve hose.

g. Connect brake booster hose.

h. Reconnect the following electrical connectors:

- ISC solenoid.

- Instrument panel temperature gauge.

- Three (3) ground wires.

NOTICE: The three (3) ground wires were originally attached to the lower back part of the intake manifold. The wires must now be rerouted to the right side runner of the new intake manifold. Also, the EGR VSV electrical connector should be taped back to the wiring harness.

9. Install new throttle body.

a. Install new throttle-body-to-intake-manifold gasket onto new throttle body unit.

NOTICE: Be sure all of the old throttle body gasket has been removed before installing the throttle body to the intake manifold.

b. Install throttle body to intake manifold.

c. Install throttle body attaching fasteners (4). Tighten to 2.0 Nm (18 lb. in.).

d. Connect accelerator cable to throttle lever and bracket.

e. Connect two (2) fuel feed and return hoses.

f. Connect coolant lines.

g. Connect various vacuum lines except for lines to the three front connectors of the throttle body. These lines will be connected in steps 10g - 10m.

h. Connect the following electrical connectors:

- Coolant temperature sensor.

- Fuel injector.

- Throttle switch (manual transmission) or throttle position sensor (automatic transmission).

10. Install new distributor.

a. Align distributor shaft drive gear mark with distributor housing marks.

b. Install distributor to cylinder head.

c. Install two (2) flange bolts and tighten.

d. Connect electrical connector.

e. Connect three (3) spark plug wires.

f. Connect coil wire.

g. Connect new 380mm length vacuum hose (Fig. 1, #3) from vacuum controller (distributor) top connection (furthest away from distributor body) to gas filter (Fig. 1, #6 - vacuum source at intake manifold).

h. Connect new 280mm length vacuum hose (Fig. 1, #2) from vacuum controller (distributor) top connection vacuum controller (distributor) bottom connect connector (closest to distributor body) to center connector of 3 connectors on the front of TBI.

i. Attach both 280mm (Fig. 1, #2) and 380mm (Fig. 1, #3) vacuum hoses to the intake manifold near extreme left hand side (driver side) using vacuum hose clamp (Part # 96055329 - Fig. 1, #4) provided in kit and bolt previously removed.

j. Attach 380mm vacuum hose (Fig. 1, #3) to PCV hose from cylinder head cover with PCV and vacuum hose clip (Part # 96056807 - Fig. 1, #5) provided in kit.

k. Connect hose (existing) from evaporative canister to left hand (driver side) hose connector of 3 connectors on the front of TBI.

l. Attach evaporative canister hose to 280mm vacuum hose (Fig. 1, #2) using clip (Fig. 1, #7) previously removed.

m. Install vacuum plug (Part # 96051388 - Fig. 1, #1) provided in kit to the right hand (passenger side) hose connector of three connectors on front of throttle body.

For MS and MR models:

11. Replace ECM.

NOTICE: For MS vehicles, it is first necessary to disconnect the negative battery cable prior to proceeding with the ECM replacement. This cable was disconnected on MR vehicles in Step 2f.

a. Remove passenger compartment fuse block located left of steering column.

b. Remove 3 fasteners holding ECM to bracket.

c. Disconnect ECM connector.

d. Remove ECM.

e. Install new ECM (Use part listed in "PARTS INFORMATION" section of this bulletin which is appropriate to the vehicle model and transmission type).

f. Connect ECM connectors.

g. Reinstall three (3) fasteners and tighten securely.

h. Reinstall fuse block to mounting bracket.

12. Reconnect negative battery cable.

13. Install new emission control information label in place of existing label.

For MR models onlv:

14. Install air cleaner assembly to throttle body.

NOTICE: Remove EGR valve modulator bracket from air cleaner body prior to installation.

15. Replenish coolant.

16. Set ignition timing per new underhood emissions label.

For MS and MR models:

17. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include 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 for periodic servicing by the owner. Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below: * FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS -------------------- -- ------- ----- ----- ------ --- --- Inspect - Cal. Emiss. SK-00 V6040 0.2 0.1 License/Reg. in Cal. 1

Inspect/Repair - Cal. Emiss. Not In Cal. 2 30002868 ** SK-00 V6041 0.4 0.1 MS Model Metro (No Diagnosis Req.)

Inspect/Repair - Cal. Emiss. Not in Cal. 12 30002870 ** SK-00 V6042 1.3 0.1 MR Model - Metro LSi

*Campaign Administrative Allowance.

**The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Chevrolet Geo Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1989 Chevrolet Geo Metro and Metro LSi model vehicles equipped with California emissions systems were distributed in states other than California. This condition could cause an involved vehicle to fail a state mandated emissions test.

WHAT WE WILL DO

To correct this condition, your Chevrolet Geo dealer will inspect the emission control system on your vehicle to determine if it has the correct system. If not, the correct system will be installed at no charge to you.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service inspection/correction is approximately one hour and thirty minutes. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Should your dealer not schedule a service date within a reasonable time, you should contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

If your dealer and the Customer Assistance Center are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturer's operations Division (EN-340F), United States Environmental Protection Agency, 401 M Street. S.W., Washington, D.C. 20460.

To ensure your full protection under the emission warranty made applicable to your vehicle by 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 test if this recall work 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.

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.