Sunfire L4-138 2.3L DOHC VIN D MFI (1995)
in this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends
that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper
maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.
Dealer Campaign Responsibility
All unsold new vehicles in dealers possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this
campaign bulletin BEFORE customers take possession of these vehicles.
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.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the
dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in
this bulletin. This could be done by mailing to such customers a copy of the customer letter shown in this bulletin. Campaign follow-up cards should not
be used for this purpose, since the customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the
steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
Disclaimer
Service Procedure
1.
Disconnect the negative battery cable.
2.
Remove the right-hand engine splash shield (in front of the right tire assembly).
3.
Remove the horn attachment bolt. Disconnect the wire and remove the horn.
4.
Remove the PCM retainer attachment bolts (2). Slide the PCM and the 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 that 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(R) 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 the PCM.
^
For 1995 vehicles: Transfer the EPROM (memcal/ESC module) from the original PCM to the replacement PCM. Proceed to Step 10.
^
For 1995 vehicles with LD2/MN4 or for 1996 vehicles: Transfer the knock sensor (ESC) module from the original PCM to the replacement
PCM. Proceed to Step 10.
9.
If the original PCM is to be placed in the vehicle, then the exterior surface must be thoroughly cleaned with a 3M Scotch Brite(R) 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.
