GEN. LIGHT IS ON/IGNITION OFF (AND/OR NO GENERATOR OUTPUT). Pontiac LeMans 1989

For 1990-2009 cars

# GEN. LIGHT IS ON/IGNITION OFF (AND/OR NO GENERATOR OUTPUT)

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

#### Models: 1989 Optima W/2.0L LT2 Engine

#### TO: ALL GENERAL MOTORS AND PASSPORT DEALERS:

General Motors of Canada has determined that certain 1989 Optima with 2.OL engines 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, dealers will revise the generator output wires.

#### VEHICLES INVOLVED:

Involved are certain 1989 Optima produced within the following VIN breakpoints:

YEAR PLANT FROM THROUGH OPTIONS ---- ----- ---- ------- ------- 1989 Pupyong SOP EOP 2.0L Engine (RPO LT2)

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY:

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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, you are to ensure the campaign correction has been made before selling 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 modification according to instructions contained in this bulletin.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ---------------- 6292995 Wire (6" - 2mm Fusible Link) 1 2077489 Eye Terminal (Ring) 1 8919355 1/2" Conduit 15" Long 1 3816659 Tie Straps 1 10463133 Generator As Required

Procure Following Parts Locally: 8 Gauge Wire 14" Long 3'Electrical Tape

#### PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card, RAPID terminal or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Repair Wires .7

3A Replace Wires and Alternator 1.1

Time allowance includes 0. 1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

#### SERVICE PROCEDURE:

1. Disconnect positive battery cable.

2. Remove the generator output wire 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 1MM fusible link generator output wire from the starter solenoid and cut if 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 gauge 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.

#### INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

#### VEHICLE RECALL NOTICE

September 1990

Dear Passport Customer:

General Motors of Canada has determined that the 1989 Optima equipped with the 2.OL OHC 4 engine may develop a condition where the generator light stays on with the ignition off or has no generator output.

To prevent the possibility of this condition occurring, your dealer will revise the generator output wires. This service will be performed for you at no charge.

Please contact your Passport dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

Further information, if required, may be obtained by calling the Passport Answer Line at 1-800-263-1999 from 8:00\a.m. to 5:00\p.m. Eastern Time, Monday to Friday.

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.