CHECK ENGINE Light ON, Engine Runs Rough (Inspect, Clean/Replace and Seal PCM, and Install Protective PCM Shield Assembly)

General Motors of Canada Limited has decided that certain 1995-96 Chevrolet Cavalier and Pontiac Sunfire 'J' car model vehicles may exhibit symptoms resulting in the illumination of the 'Check Engine' light or the engine runs rough. If these symptoms are ignored the engine may stall and may not be able to be restarted. This may be due to moisture entering the Powertrain Control Module (PCM), as a result of corrosion.

To correct this condition, dealers are to inspect, clean and/or replace the Powertrain Control Module (PCM), then seal the PCM in a protective shield/cover assembly.

Involved are certain 1995-96 Chevrolet Cavalier and Pontiac Sunfire (J-Car) model vehicles built within the following VIN breakpoints:

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data will be prepared, furnished to involved dealers as the parts become available. The customer name and address data furnished at that time will enable dealers to follow-up with customers involved in this campaign.

These dealer listings may contain customer names and addresses obtained from the Inter-Provincial Records. The use of such motor vehicle registration data for any other purpose is a violation of provincial laws. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Important: TO HELP INCREASE THE FLOW OF CRITICAL PARTS, DEALERS MUST RETURN ALL PCM CORES TO THEIR LOCAL PDC IMMEDIATELY AFTER COMPLETION OF REPAIRS.

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.

All customers of record, in the high corrosion provinces, will be notified by first class mail from General Motors.

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.

1. Disconnect the negative battery cable.
2. Remove the right-hand engine splash shield (in front of the right front tire assembly).
3. Remove the horn attachment bolt, disconnect wire and remove horn.
4. Remove the PCM retainer attachment bolts (2), slide PCM and retainer from the PCM bracket. Remove the retainer from the PCM.
5. Disconnect the PCM from the harness.
6. With the PCM harness disconnected, inspect the green weatherpack seal to ensure the seal is intact and sealing properly to the wires and the body of the connectors.
7. Visually inspect the PCM for signs of corrosion or corrosion debris.

•	If no corrosion is visually present, proceed to step 10.

•	If the PCM case has light surface corrosion which could be cleaned using a Scotch Brite® or equivalent pad, especially where the two case halves seal and where the connectors seal to the case, proceed to step 9.

•	If the PCM case has significant surface corrosion, especially where the two case halves seal and where the connectors seal to the case, proceed to step 8.

8. Replace PCM,

•	1995 Vehicles -- Transfer the EPROM (memcal/ESC module) from the original PCM to the Replacement PCM. Proceed to step 10.

•	1996 Vehicles -- Transfer the knock sensor (ESC) module from the original PCM to the Replacement PCM. Proceed to step 10.

Important: 

•	The harness assembly will not seal if the sealing shroud of the PCM is damaged.

•	The areas to be sealed must be thoroughly cleaned before applying the RTV Silicone Sealer. Failure to properly clean and prepare the surfaces to be sealed may result in an ineffective seal, which could allow moisture to enter the PCM case.

9. If the original PCM is to be placed back in vehicle, then the exterior surface must be thoroughly cleaned with a 3M Scotch Brite® or equivalent pad. Do not open the case and clean any internal surfaces. Also, the inside of the sealing shrouds for the connector must be CLEAN. Inspect for any obvious signs of damage to the sealing shroud such as cracks, pitting from corrosion, or corrosion debris that cannot be removed. Do not wire brush or file the sealing surface smooth. If any such conditions exist, the PCM must be replaced. Proceed to step 10.



10. The following procedure applies to original or new PCMs:

Using a clean shop cloth, spray 'brake clean', P/N 12377981 and/or equivalent, onto the shop cloth (do not use Carb Cleaner as it will leave an oil residue). Clean the areas to be sealed on the PCM (do not spray directly onto the PCM). Apply RTV silicone sealer, P/N 12346286 and/or equivalent, to the entire perimeter of the PCM case, screws and any areas where water may enter the case of the PCM Apply the RTV silicone sealer to the KS Module or EPROM access cover and allow to setup before reinstalling in vehicle.




11. Apply lubricant (P/N 12377900) to the weatherpack seal surface area of the connectors and reconnect the harness to the PCM.
12. Reinstall the plastic retainer to the PCM.
13. Install the PCM cover (P/N 22623903) over the PCM with "F" facing outward.
14. Install the PCM into the vehicle bracket.



15. Install the PCM shield assembly (P/N 22623904) to vehicle. Drape the shield over the PCM bracket. Remove the evap hose clip fastener and reinstall through the shield. Push the square cut out over the PCM attachment nut. Remove the horn wiring attachment clip and reinstall through shield.



16. Install the push-in retainer (P/N 10121502) through the lower front hole of the PCM shield and then through the side hole of the PCM cover.
17. Reprogram new PCM (1996 only).
18. Install 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. Additional Campaign Identification Labels can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm Eastern Standard Time). Ask for Item Number GMP 91 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.

It is not expected that there would be owner reimbursement associated with this campaign since the affected component is covered by the 8 year/130,000 km emission control systems warranty.

If an owner requests a reimbursement for previously completed repairs, this must be considered on a case by case basis as follows:

Consideration for reimbursement will be allowed only if genuine General Motors parts were used. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Notice: Refer to the service policies and procedures manual, section 1.6.1, for specific procedures regarding customer reimbursement verification.