GENERATOR LIGHT ON W/ IGNITION OFF AND NO CHARGE. Pontiac LeMans 1989

For 1990-2009 cars

# GENERATOR LIGHT ON W/ IGNITION OFF AND NO CHARGE

#### Subject: GENERATOR LIGHT "ON" WITH IGNITION OFF AND/OR NO GENERATOR OUTPUT

#### MODELS AFFECTED 1989 PONTIAC LEMANS WITH 2.0L LT2 ENGINE

General Motors has determined that some 1989 Pontiac LeMans with 2.0L TBI Engine (RPO LT2) may develop a condition whereby the generator light stays on with the ignition off or has no generator output. The fusible link may overheat and cause loss of insulation from adjacent wires. This may result in an electrical short between the generator output lead' and lamp wire causing a regulator failure.

To prevent the possibility of this condition occurring, dealer will revise the generator output wires,

#### VEHICLES INVOLVED

Involved are certain 1989 Pontiac LeMans produced within the following VIN breakpoints: Up To And Year Plant Beginning Including

1989 Pupyong KB315641 KB368546

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 the 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 Pontiac 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 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 used 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 Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered on a C.I.O. order with no special instruction code, but on advise code (2).

Part Quantity Description Number Per Vehicle -------------------------- ------- ------------ Wire (6" - 2m Fusible Link) 6292995 Eye Terminal (Ring) 2977489 1/2" Conduit 15" Long 8919355 1 Tie Straps 3816659 1 Generator 10463133 As Req'd

Procure the following parts locally:

8 Gage Wire 14" Long 3 Electrical Tape

#### SERVICE PROCEDURE

1. Disconnect positive battery cable.

2. Remove the generator output wire (red) and cut it off even with the conduit. Save the end for terminal size.

3. Cut off the voltage regulator sense wire (red) from the two pin generator connector and cut the remaining wire even with the conduit, The regulator does not need this wire and can sense voltage from the output wire.

4. Unbolt the IMM fusible link generator output wire from the starter solenoid and cut it off even to the conduit. Save the end for terminal size.

5. Make a new generator output wire:

a. Use a 6" 2MM fusible link with an eye terminal to fit the starter solenoid.

b. Connect the fusible link to a 14" long 6MM or 8 gage wire. Solder the connection and tape over with high temperature tape.

C. Install an eye terminal to fit the generator output stud.

d. Cover complete wire except fusible link with a length of plastic conduit and tape in place.

6. Install new generator output wire and tie-strap in place.

7. Install positive battery cable and two pin generator connector. With ignition on, the generator light should be on.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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, the five digit dealer code of the dealer performing the campaign service and the date the vehicle was campaigned. This information may be inserted with a typewriter or ball-point pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7901-709).

#### CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion. DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Replace Wires 96 V6260 0.6 0.1

Replace Wires and Alternator 96 V6261 1.0 0.1

Owner Reimbursement for Previous Repairs 96 T3254 ---- ----

* In addition, dealerships will receive 0.1 hours credit for dealer adminis- trative services associated with this campaign, The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.

The "Parts Allowance" should be the sum total of the current GMSPO dealer Net price plus 30% handling allowance of all parts required for repairs performed in accordance with this bulletin.

Total reimbursement amount requested should be shown in the sublet column.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

#### RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid. Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

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.