Product Emission - Loose Spark Plug Center Wire

THIS RECALL IS IN EFFECT UNTIL NOVEMBER 30, 2003.

General Motors has decided to conduct a Voluntary Emission Recall involving certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61). Some of these vehicles may have been built with spark plugs that misfire. If a spark plug misfires, it could result in illumination of the Service Engine Soon Light/Check Engine Light and/or engine misfire and roughness.

Dealers are to inspect the spark plug(s) and replace them if necessary.

Involved are certain DEALER INVENTORY 2003 and 2004 model year Chevrolet TrailBlazer and TrailBlazer EXT, GMC Envoy and Envoy XL, and 2004 model year Oldsmobile Bravada vehicles equipped with a 4.2L L6 engine (LL8); and 2004 model year Chevrolet Cavalier and Classic, Oldsmobile Alero, and Pontiac Grand Am and Sunfire vehicles equipped with a 2.2L L4 engine (L61) and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] Use the spreadsheet (sent in a separate message) until the VINs are loaded into the GMVIS (GM Vehicle Inquiry System), GM Access Screen (Canada only), and DCS Screen 445 (IPC).

Parts required to complete this recall 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: The labor time allowance listed in this recall is different than that currently published in the labor time guide for performing the same operation. In the near future, the labor time guide will be updated with this new information.

1. If the vehicle has an L6 engine, remove the #2 spark plug.
2. If the vehicle has an L4 engine, remove the #1 spark plug.

Important: In the next step, there will be a 6-digit number stamped on the spark plug. The first 3 numbers are the date code.




3. Inspect the spark plug for a date code. Refer to the illustration above.

203 = Date Code

3 = Year

1 = Line

1 = Shift

•	If the date code on the spark plug is 154, 155, or 156, REPLACE THE SPARK PLUG. Inspect the rest of the spark plugs and replace the ones that have the date codes 154, 155, or 156.

•	If the date code on the spark plug is NOT 154, 155, or 156, the spark plugs are not suspect. Reinstall the same spark plug. No further inspection is required on the rest of the spark plugs.

4. Install the GM Recall Identification Label.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall 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.

For US and IPC

When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. or 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Recall Claim with the information indicated below.

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

There will be no customer notification. This recall is for vehicles in dealer inventory only.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall through November 30, 2003.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory prior to November 30, 2003, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.