VARIOUS DRIVEABILTY CONDITIONS (REPAIR OVERSIZED TERMINALS). Pontiac Tempest (Canada) 1992

For 1990-2009 cars

# VARIOUS DRIVEABILTY CONDITIONS (REPAIR OVERSIZED TERMINALS)

#### SUBJECT VARIOUS DRIVEABILITY CONDITIONS (REPAIR OVERSIZED TERMINALS)

VEHICLES AFFECTED: 1992 B, E, L, N MODELS 1992 C/K TRUCKS AND G, L, M VANS

APPLICATIONS: (ENGINES)

2.3L (VIN A,D,3 / RPO LGO, LD2, L40)

3.1L (VIN T / RPO LHO)

3300 (VIN N / RPO LG7)

3800 (VIN L / RPO L27)

4.3L (VIN Z,W / RPO LB4, L35)

5.OL (VIN E,H / RPO L03)

5.7L (VIN 7,K/ RPO L05)

#### CONDITION:

Some owners of the vehicles listed below may experience various driveability conditions such as reduced fuel economy, SES light, runs rough, misses, etc. (specific concerns are described in the following paragraphs). If diagnosis indicates a need to replace any control system components (example, ECM or sensors), check suspect connector terminals and repair if necessary prior to replacing the control system component.

#### NOTE: Refer to attached "PASSENGER CAR" SYMPTOM CHART and "TRUCK" SYMPTOM CHART.

#### CAUSE:

The condition may be a result of intermittent or open circuits caused by insufficient contact between the ECM harness female terminal and the mating ECM male pin. Some of the 12089649 micro-pack 100 series female terminals (formerly P/N 12020757) could have an oversized contact area condition.

#### NOTE: Either terminal may be used in repair.

#### VIN BREAKPOINTS:

Suspect vehicle VIN breakpoints for PASSENGER CARS follow:

#### Willow Run

Beginning VIN Ending VIN Nameplate

lGlBN53ElNW135953 1GlBN53E6NW138380 Chevrolet lGlBL83E5NW135087 1GlBL83E5NW138796 Chevrolet lG3BP83E7NW303548 1G3BP837XNW303853 Oldsmobile lG4BR8379NW408304 1G4BR9079NW408934 Buick lG3BP8375NW303629 1G3BP8375NW303825 Oldsmobile lG4BR8372NW408277 1G4BR907XNW408800 Buick lGlBL53Z9NW134624 lGlBL53Z5NW138153 Chevrolet (LB4)

#### Arlington

lGlBL5373NR133692 lGlBL5374NR143714 Chevrolet lG4BT537XNR460609 lG4BN5379NR468100 Buick

#### Hamtramck

1G4EZ13L5NU007780 1G4EZ13L5NU009103 Buick

#### Lansing

1G2N*****NC270041 1G2N*****NC277757 Pontiac lG2N*****NM077482 1G2N*****NM084066 Pontiac lG3N*****NM450908 1G3N*****NM457343 Oldsmobile lG4N*****NC648484 lG4N*****NC651304 Buick

Wilmington** ----------

lGlL*#3T@NY239772 lGlL*#3T@NY254066 Chevrolet lGlL*#3T@NY700980 lGlL*#3T@NY701089 Chevrolet

* Any one of T,V,W carline series codes ** Multiple codes possible for certain positions on VIN # Either 1 or 5 -- 2-door or 4-door code @ is a check digit; range from 0 - 9 or "X"

VIN BREAKPOINTS: (continued)

Suspect vehicle VIN breakpoints for TRUCKS follow:

#### Oshawa

Beginning VIN Ending VIN Nameplate

2GCEC19ZON1213269 2GCEC19K2Nl2l7746 Chevrolet 2GTEC19K7Nl540187 2GTEC19K2Nl541957 GMC

#### Pontiac East

1GCDC14Z5NE182893 1GBJC34K7NE187129 Chevrolet IGTEC14HlNE529454 1GTEK14Z9NE534123 GMC 1GCEK14Z3NE190742 1GBGK24K7NE191513 Chevrolet 1GTEC14K0NE536004 1GTDC14Z2NE536353 GMC

#### Fort Wayne

1GCDC14Z0NZ188089 1GCEK14K6NZ192898 Chevrolet 1GTDC14Z0NZ529877 1GTEC14H4NZ531286 GMC

#### Baltimore

1GNEL19WGNB178637 1GNDM19W5NB194028 Chevrolet 1GKDL15WlNB527573 1GKEL19WlNB534456 GMC

#### Scarborough

2GBEG25K9N4132342 2GCEG25Z9N4147935 Chevrolet 2GTGG39K8N4515208 2GDHG31K3N4522546 GMC

#### Lordstown

1GNEG25K8N7124997 1GCCG15H8N7132502 Chevrolet 1GTEG25Z7N7510624 1GKEG25KXN7513752 GMC

#### CORRECTION:

1. To check for an oversize terminal, use a #62* drill bit (.038 inches,/.965 mm) and place a mark 1/2 inch up from the bottom of the shank of the drill bit. Place a flag made from tape at the mark on the drill (see Figure 1).

2. Remove connector from ECM and hold connector vertically up.

3. Place shank of #62* drill bit (.038 inches,/.965 mm) in connector cavity of suspect terminal. Do not push on drill (see Figure 2).

4. Repair any terminal allowing drill bit to fall unassisted to the flag on drill bit. Any terminals having resistance or drag or not allowing drill to enter terminal are okay and do not need repair. Repair any over sized terminal as described in steps 5 through 8.

5. Remove the TPA (terminal position assurance) from the connector.

6. Remove the terminal from the connector using terminal removal tool GM 12031876-1 (Kent-Moore Tool No.J38125-A).

7. With a pair of small needle nose pliers, resize the contact area of the terminal as shown in Figure 3.

8. To verify the terminal has been adequately sized, insert a #63* drill bit (.037 inches,/.940 mm) into the contact area as shown in Figure 4. If resistance can be felt against the bit in the resized area, resizing is complete. If no resistance is felt, repeat steps 7 and 8.

9. Raise the terminal lock tang (Figure 4) so the terminal can be properly held in the connector.

10. Reinsert the terminal into the proper connector cavity.

11. Reinsert the TPA into the connector.

12. If the terminal becomes severely damaged by using this method, replace the terminal using established terminal replacement procedures.

13. Reinstall harness to ECM and perform any required relearn procedure prior to continuing diagnosis.

* NOTICE: Measure drill to ensure drill is of proper diameter. A larger sized drill will damage a good terminal.

For vehicles repaired under warranty:

Use applicable labour operation and time allowances.

SYMPTOMS (Trucks) - Continued

Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s) ------ ------- ---------- ---------- ----------

#### 1992 G Van (continued)

5.7L(L05) MTl-4L80E 435 A11/GRY 1. SES light "on" JA4 EVRV(EGR) 2. Code 32 stored control 3. Rough idle 4. Poor fuel economy 5. Hesitates 6. Stall at idle 7. Intermittent circuit may or may not set code 32

5.7L(L05) MTl-4L80E 420 A12/PPL 1. No TCC JA4 Brake signal 2. No shift to 4th gear 3. Poor fuel economy 4. Intermittent circuit will cause erratic Tech 1 readings

4.3L(LB4) MT8-4L60 452 Al1/BLK 1. SES light "on' JA4 CTS & TPS 2. Codes 15 and/or 21 and/or 45 sensor stored ground 3. High idle 4. Poor fuel economy 5. Engine runs rich 6. Hard start 7. Hesitates 8. Surges 9. Stall 10. No power 11. Exhaust odor 12. Intermittent circuit may or may not set codes 13. Intermittent circuit will cause erratic Tech 1 readings

SYMPTOMS (Trucks) - Continued

Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s)

#### 1992 G Van

5.0L(L03) MD8-4L60 *450 D1/BLK/WHT 1. Poor fuel economy 5.7L(L05) Trans System 2. Erratic engine operation ground 3. Stalls 4. No start 5.7L(L05) MTl-4L80E *551 C3/Tan/WHT 5. Quit JA4 *450 C2/BLK/WHT 6. Hard start 92C(SEO) 7. Flickering SES light 8. No codes stored * The terminals for system ground 9. Hesitates circuits 450 and 551 must both be 10. Surge replaced on G vans if any one of 11. Intermittent circuit will the ground terminals is found faulty. cause erratic Tech 1 Use established replacement procedures. readings

5.0L(L03) MD8-4L60 441 C5/LtBLU/WHT 1. Stalls 5.7L(L05) JA4 IAC"A"Hi 2. Low or high idle 3. Intermittent circuit could 5.7L(L05) MTl-4L80E 441 cause erratic idle JA4 IAC"A"Hi

5.0L(L03) MD8-4L60 437 AI0/BRN 1. SES light "on" 5.7L(L05) JA4 VSS 2. Code 24 stored 3. Unstable idle 4. Intermittent circuit may or may not set code 24 5. No TCC 6. Poor fuel economy 7. Intermittent circuit will cause erratic Tech 1 readings

5.7L(L05) MTl-4L80E 437 Bll/BRN 1. SES light "on" JA4 VSS 2. Code 24 stored 3. No shift beyond 2nd 4. Intermittent circuit will cause erratic Tech 1 readings

5.7L(L05) MTl-4L80E 496 D5/DkBLU 1. SES light "on" JA4 ESC (knock) 2. Code 43 stored signal 3. Spark knock 4. Intermittent circuit may or may not set code 43

5.7L(L05) MD8 467 D16/BLU 1. Detonation 4L60 Injector 1 2. No power 3 Hard start 4. Rough idle 5. SES light "on' 6. Code 43 and/or 44 stored 7. Miss 8. Hesitates 9. Surge 10. Quit 11. Intermittent circuit may or may not set codes

SYMPTOMS (Trucks) - Continued

Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s)

1992 C/K Trucks (Regular or Extended Cab) GVW less than 7200 lbs. ----------------------------------------

5.0L(L03) MG5/MT8 413 D6/TAN 1. SES light "on" 5.7 (L05) Man tran 02sensor 2. Code 13 stored ground 3. Stalling 4. Detonation 5. Surge 6. Hesitates 1992 C/K Trucks (Regular or Extended Cab) All Series 7. Engine runs rough ---------------------------------------- 8. Intermittent circuit may or 5.0L(L03) MD8-4L60 413 D6/TAN may not set code trans 02sensor 13 ground 9. Erratic engine operation 10. Intermittent circuit will cause erratic Tech 1 readings

1992 C/K Trucks (Regular or Extended Cab) 10 & 20 Series ----------------------------------------

5.7L(L05) MD8-4L60 413 D6/TAN trans 02sensor ground

1992 C/K Trucks (Regular, Extended, or Crew Cab) 8600 GVW & over -----------------------------------------------

5.7L(L05) MT8 413 D6/TAN Man tran 02sensor ground

1992 M/L Van ------------

4.3L(L35) All 120 B2/GRY 1. SES light "on" Fuel pump 2. Code 54 stored signal 3. Intermittent circuit will cause erratic Tech 1 readings

4.3L(L35) All *450 A12/BLK 1. Erratic engine Ground operation 2. Stalling 3. Surge 4. Flickering SES light 5. No codes stored 6. No start 7. Quit 8. Hesitates * The terminals for system ground 9. Poor fuel economy circuits 450 and 551 must both be 10. Hard start replaced on M/L vans if any one of 11. Intermittent the ground terminals is found faulty. circuit will Use established replacement procedures. cause erratic Tech 1 readings

SYMPTOMS (Passenger Car)

Connector Cavity/ Engine Options Circuit(s) Wire Color Symptom(s)

1992 Caprice/Custom Cruiser/Roadmaster ---------------------------------------

All All 419 A5/BRN/WHT 1. SES light will SES light not illuminate driver

All All 467 D16/DkBLU 1. Detonation Injector 1 2. No power 3. Hard start All All 468 D14/DkGRN 4. Rough idle Injector 2 5. SES light "on" (if circuit 419 okay) 6. Code 43 and/or 44 stored 7. No start if both circuits open 8. Miss 9. Hesitates 10. Surge 11. Quit 12. Intermittent circuit may or may not set codes

1992 Riviera

3800 (L27) All 630 A12/BLK 1. SES light "on" VIN L Cam sensor 2. Code 41 stored 3. Stalls 4. Runs rough

1992 Corsica/Beretta

3.1 L (LHO) All 410 E16/YEL 1. SES light "on" VIN T Cool. temp. 2. Code 15 stored sensor 3. Runs rough 4. Hard start 5. Floods (except in very cold ambient) 6. Reduced fuel economy 7. Exhaust odor 8. No power 9. Cooling fan always on under 35 MPH 10. Intermittent circuit may or may not set code 15 11. Intermittent circuit will cause erratic Tech 1 readings

1992 Grand Am/Achieva/Sky Lark

2.3L (LD2) All 888 C15/DkBLU 1. SES light "on" VIN D Injectors 2/3 C13/DkBLU 2. Codes 44 and/or 65 stored (L40) All 3. No start VIN 3 4. Stalls (LGO) All 5. Hard start VIN A 6. Detonation 7. No power 8. Intermittent circuit may or may not set codes

3300 (LG7) All 639 A6/PNK/BLK 1. Stalls VIN N Ignition 2. Stumbles 3. SES light flashing 4. No codes stored 5. No SES light 6. No start 7. No ALDL data 8. Intermittent circuit will cause erratic Tech 1 readings

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.