*** Moderators I ask for this to be a sticky for the org. Thank-you***
JBO, these are GM's
Technical
Service
Bulletins, a.k.a. TSBs. The purpose of this is to give information on how to fix problems that are recognized by the auto manufacturer.
These fixes (should) be free of charge if you are covered by the manufacture's warranty. If not you may be charged.
THESE ARE NOT RECALLS. Recalls are when the item has a safety concern and therefore the dealer will take care of it free of charge no matter how old.
If you would like to perform these fixes, go to your dealer's service department with TSB# and ask politely to a service writer or a person of trust for the info on the TSB. A complete summery of the issue with part #s and labor time will be available.
Towards the end you will see other issues related to the J-body.
Best of luck to all.
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*J-body Bulletins*
1. 99-03-08-004: 1996-99 Chevrolet Cavalier, 1997-99, Chevrolet Malibu, 1997-99 Oldsmobile, Cutlass, 1999 Oldsmobile Alero, 1996-99 Pontiac Sunfire, 1999 Pontiac Grand Am; Front And/Or Rear Stabilizer Shaft Squawk/Squeak Noise (Replace Front And/Or Rear Bushings). SUSPENSION 10-99
2. 99-01-38-003: 1997-2000 Chevrolet Cavalier, 1997-2000 Pontiac Sunfire With 2.2L Engine (VIN 4 – RPO-LN2);Engine/Transmission Whine At 2800-3200 RPM (Replace Heater Inlet Hose). HVAC 11-99
3. 99-06-02-015: 1998-2000 Chevrolet Cavalier, 1998-2000 Pontiac Sunfire With 2.2L, L-4Engine (VIN 4 – RPO LN2); Upper Radiator Hose Replacement. ENGINE/PROPULSION SYSTEM 11-99
4. 99-08-64-026: 1995-2000 Chevrolet Cavalier Convertible,1995-2000 Pontiac Sunfire Convertible; Door Rattles When Closing (Adjust Bracket/Install Tape). BODY AND ACCESSORIES 12-99
5. 99-07-30-031: 1999-2000 Chevrolet Cavalier,Malibu,1999 Oldsmobile Cutlass,1999-2000Oldsmobile Alero,1999-2000 Pontiac Grand-AM, Sunfire With Hydra-Matic 4T40-E,4T45-ETransaxle (RPOs MN4,MN5)And 2.2L,2.4L, 3.0L,3.1L Or 3.4L Engine (VINs 4,F,T,R,M,E,-RPOs LN2,L61,LD9,L81,L82,LA1);99-07-30-031;No Third And Fourth Gear (Replace Direct Clutch Piston Assembly). TRANSMISSION/ TRANSAXLE 2-00
6. 99-07-29-007: Manual Transaxle Exchange Program; 2000 Chevrolet Cavalier, 2000 Oldsmobile Alero, 2000 Pontiac Grand Am, Sunfire, with F23 Manual Transaxle. TRANSMISSION/TRANSAXLE 3-00
7. 00-06-01-002: Revised Timing Chain, Sprockets, Tensioner Installation Procedure; 1998-1999 Chevrolet Malibu, 1998-2000Chevrolet Cavalier, 1998 Oldsmobile Achieva, 1999-2000 Oldsmobile Alero, 1998-2000 Pontiac Grand Am, Sunfire, with 2.4L Engine (VIN T – RPO LD9) ENGINE/PROPULSION SYSTEM 4-00
8. 00-06-04-009: Rough Engine Idle, Misfire, Possible DTC P0300 (Replace Spark Plug Boot Assembly); 1999 Chevrolet Malibu, 1999-2000 Chevrolet Cavalier,1999-2000 Oldsmobile Alero, 1999-2000Pontiac Grand Am, Sunfire, with 2.4LEngine (VIN T – RPO LD9). GENERAL INFORMATION 4-00
9.00-00-89-008: Replaces 16-01-01B; Recreational (Dinghy) Towing; 1995-2000 Chevrolet Cavalier, 1997-2000 Chevrolet Malibu, 1995-98 Oldsmobile Achieva, 1997- 99 Oldsmobile Cutlass, 1999-2000 Oldsmobile Alero, 1995-2000 Pontiac Grand-Am, 1995-2000 Pontiac Sunfire, With Hydra-Matic® 4T40-E or 4T45-E Automatic Transaxle (RPOs MN4, MN5) or 5-Speed Manual Transaxle (RPOs MK7, MJ1), 1999-00-05-24-001. GENERAL INFORMATION 6-00
10. 00-05-24-001: Snow Intrusion Into Rear Drum Brake Assemblies (Replace Rear Brake Assembly Backing Plates); 1985-87 Buick Somerset, 1985-89 Buick Skyhawk, 1985-98 Buick Skylark, 1985-88 Cadillac Cimarron, 1985-2000 Chevrolet Cavalier, 1985-88 Oldsmobile Firenza, 1985-91 Oldsmobile Cutlass Calais, 1992-98Oldsmobile Achieva, 1985-94 Pontiac Sunbird, 1985-98 Pontiac Grand Am, 1995-2000 Pontiac Sunfire. BRAKES 6-00
11.00-06-04-015: New Design Quick-Connect Fuel Line Fittings; 2000 Chevrolet Cavalier, Malibu, 2000 Oldsmobile Alero, 2000 Pontiac Grand Am, Sunfire. ENGINE/PROPULSION SYSTEM 6-00
12. 00-08-49-003: Rattle/Squeak in Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of Instrument Panel Contacting Door Trim Panel (Remove Instrument Panel Assembly and Align Tie Bar); 1995-2000 Chevrolet Cavalier and Pontiac Sunfire. BODY AND ACCESSORIES 7-00
13. 00-07-30-013: Forward Clutch Piston Change on 4T40-E/4T45-E Automatic Transaxles; Adapter);1999-Cavalier,Malibu,1998-99 Oldsmobile Cutlass,1999-2000 Oldsmobile Alero, 1998-2000 Pontiac Sunfire,1999-2000 Pontiac Grand Am, With 4T40-E or 4T45-E (RPOs MN4,MN5)Automatic Transaxle .TRANSMISSION/TRANSAXLE 8-00
14. 00-07-30-014: Vehicle Slips in Reverse, No Reverse, Slips in D1,or NoD1 Range (Replace Reverse Oil Pipe Seal);2000 Chevrolet Cavalier,2000Pontiac Sunfire, With 2.2L Engine (VIN 4– RPO LN2))and Hydra Matic ® 3T40 Transaxle/Transmission (RPO MD9) (Transmission built between Julian dates (9270-9292). TRANSMISSION/TRANSAXLE 9-00
15.00-06-01-018: Growl/Moan Noise During Sharp Left Turn (Modify Engine Mount Stamping):2000 Chevrolet Cavalier,2000 Pontiac Sunfire, With 2.2L Engine (VIN 4 – RPO LN2). ENGINE/PROPULSION SYSTEM 10-00
16. 99-01-39-006A: Replaces 99-01-39-006; 00-06-04-037;Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717 Set (Repair Input Speed Sensor Wiring at Transaxle Wiring Pass-thru Connector);2000-2001 Chevrolet Cavalier and Malibu,2000-2001 Oldsmobile Alero,2000-2001 Pontiac Grand Am and Sunfire,2000 Toyota Cavalier. ENGINE/PROPULSION SYSTEM 10-00
17. 00-06-04-038: Unwanted Switch to Gasoline, Fuel Indicator Lamp (FIL)Inoperative, Cooling Fan Inoperative, Engine Running Hot and/or Overheating (Replace Cooling Fan/CNG Fuse); 2000 Chevrolet Cavalier With 2.2L Engine (VIN 4 – RPO LN2))and Bi-Fuel (CNG)(RPO KL6). ENGINE/PROPULSION SYSTEM 10-00
18. 00-07-30-016: Removal of the PWM Filter From the Spacer Plate – 4T40E//4T45E Automatic Transmission;1998-2000 Chevrolet Cavalier and Malibu,1998-1999 Oldsmobile Cutlass,1999-2000 Oldsmobile Alero,1998-2000 Pontiac Sunfire,1999-2000 Pontiac Grand Am, With 4T40E or 4T45E Automatic Transmission (RPOs MN4, MN5). TRANSMISSION/TRANSAXLE 10-00
19. 00-06-04-044: Engine Hesitates, Stalls and/or Will Not Start (Replace Modular Fuel Sender Strainer);2000 Chevrolet Cavalier,Malibu;2000 Oldsmobile Alero; 2000 Pontiac Grand Am, Sunfire. ENGINE/ PROPULSION SYSTEM: 12-00
20. 00-07-30-019: SES Light Illuminated, DTC P1870 (Replace TCC Solenoid Valve); 2000 Chevrolet Cavalier, Pontiac Sunfire. TRANSMISSION/TRANSAXLE 1-01
21. 00-06-04-053: Idle Air Control Valve (IACV) Hissing Noise (Replace the IACV); 1999 - 2000 Chevrolet Cavalier, Pontiac Sunfire, Chevrolet and GMC S/T Models (S10, Sonoma) with 2.2 L Engine (VINs 4,5 -- RPOs LN2, L43). ENGINE/PROPULSION 2-01
22. 00-06-02-009: Water Pump Weep (Normal Condition); 1996 - 1998 Buick Skylark, 1996 - 2001 Chevrolet Cavalier, 1997 - 1999 Chevrolet Malibu, 1996 -1998Oldsmobile Achieva, 1999 -2001 Oldsmoble Alero, 1996 - 2001 Pontiac Grand Am, Sunfire with 2.4 L Engine (VIN T -- RPO LD9). ENGINE/PROPULSION 2-01
23. 01-02-32-001: Clunk Noise From Front Of Vehicle During Turning Maneuver /Steering Wheel Rotation (Install New Shaft); 1997-2001 Chevrolet Cavalier and Pontiac Sunfire. STEERING 3-01
24. 01-06-01-004: Hoot/Whistling Noise At Startup During Cold Ambient Temperature (Replace Idler Pulley Assembly); 1998-2001 Chevrolet Cavalier and Pontiac Sunfire with 2.2L Engine (VIN 4 -- RPO LN2). ENGINE/PROPULSION 3-01
25. 01-06-04-003: MIL Light On, DTC P0141 Set (Replace Oxygen Sensor, HO2S 2); 1996 Buick Skylark, Chevrolet Cavalier, Oldsmobile Achieva, Pontiac Grand Am and Sunfire, with 2.4L Engine. (VIN T - RPO LD9). ENGINE/PROPULSION 4-01
26. 01-06-04-008: Inaccurate or Erratic Fuel Gauge Reading (Install New Fuel Tank Sender Sensor); 2000-01 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand Am, Sunfire, Toyota Cavalier. ENGINE/PROPULSION 4-01
27. 01-07-30-003: 1995-2000 Summary of 3T40 Transaxle Technical Information (as of 11/01/00); 1995-2000 Chevrolet Cavalier and Pontiac Sunfire with 3T40 Automatic Transmission (RPO MD9). TRANSMISSION/TRANSAXLE 4-01
28.01-06-04-007A: Replaces bulletin 01-06-04-007);MIL Indicator Illuminated, DTC Code P0442 Stored (Replace Fuel Sender to Tank O-ring);2000-01 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire. ENGINE 6-01
29.01-06-04-027: Revised Fuel Gauge Inaccurate or Inoperative Diagnostic Procedure;1999 Chevrolet Cavalier and Pontiac Sunfire. ENGINE/PROPULSION 6-01
30. 01-07-30-024; Clearing Shift Adapts; 2002 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire with 2.2L Engine (VINs F, 4 -- RPOs L61, LN2) and 4T40-E Automatic Transmission (RPOMN4).TRANSMISSION/ TRANSAXLE 9-01
31. 01-07-30-026: TCC Surge/ Chuggle /Slip at 72-96 km/h (45-60 mph) with Automatic Transmission 4T40E (Reprogram PCM); 2001 Chevrolet Cavalier, Pontiac Sunfire with 2.2L engine (VIN – RPO LN2) and automatic transaxle (RPO MN4). TRANSMISSION/ TRANSAXLE 10-01
32. 01-03-10-005: Wheel Squeak (Install Wheel Cover Insulators); 2000-2001 Chevrolet Cavalier, Pontiac Sunfire. SUSPENSION 11-01
33. 01-08-44-011: CD Cannot Be Inserted Into CD Player or Ejected (Reset Radio); 2002 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture, Oldsmobile Alero, Intrigue, Silhouette, Pontiac Montana. BODY AND ACCESSORIES 12-01
34. 01-06-01-024: Engine Exchange Program for 2.2L ECOTEC Engine (VIN F --RPOL61);2002 Chevrolet Cavalier, Pontiac Sunfire. ENGINE/PROPULSION 1-02
35. 01-00-90-002: Achieving Correct Oil Level and Crankcase Capacity Revision; 2002 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire with 2.2L Ecotec Engine (VIN F, RPO L61). GENERAL INFORMATION 2-02
36. 01-02-35-010: Revised Lock Cylinder Replacement; 1995-01 Chevrolet Cavalier, Pontiac Sunfire. STEERING 2-02
37. 01-07-30-039: 4T40E or 4T45E Transmission Transaxle Changes for 2002 Model Year; 2002 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand Am, Sunfire. TRANSMISSION 2-02
38. 01-08-65-001: Fuel Filler Door Recessed Into Quarter Panel (Replace Fuel Filler Pocket); 1999-2002 Chevrolet Cavalier, Pontiac Sunfire. BODY AND ACCESSORIES 2-02
39. 01-06-01-030: Higher Than Expected Engine Oil Consumption (Replace Rocker Arm Cover); 1998-2002 Chevrolet Cavalier, Pontiac Sunfire, Chevrolet and GMC S Truck with 2.2L Engine (VINs 4, 5 – RPOs LN2, L43). ENGINE/PROPULSION 2-02
40. 01-06-04-008A: Replaces 01-06-04-008; Inaccurate or Erratic Fuel Gauge Reading (Install New Fuel Tank Sender Sensor); 2000-01 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand-Am, Sunfire with Plastic Fuel Tank. ENGINE/PROPULSION 3-02
41.02-06-01-001: Drone Noise from Engine Area (Replace Accessory Drive Belt); 1999-2001 Chevrolet Cavalier, Pontiac Sunfire with 2.2L Engine (VIN 4 --RPO LN2). ENGINE/PROPULSION 3-02
42.01-08-45-006: Availability of New Micro 64 Electrical Terminals for Wiring Repairs; 2002 Cadillac Seville, Chevrolet Cavalier, Pontiac Grand Am, Sunfire. BODY AND ACCESSORIES 3-02
43. 01-08-58-005: “Wet Road Sizzle” Noise from Rear of Vehicle (Install Wheelhouse Liners); 2000-02 Chevrolet Cavalier, Pontiac Sunfire (Coupes Only). BODY AND ACCESSORIES: 3-02
44. 02-07-29-001: Grinding/Rattle Type Noise Coming from Transmission(Diagnose and Perform Repair); 2000-02 Chevrolet Cavalier, Pontiac Sunfire, 2001-02 Oldsmobile Alero, Pontiac Grand Am with Manual Transmission (RPO M86 or M94). TRANSMISSION 4-02
45. 01-08-45-006A; Replaces 01-08-45-006;Availability of New Micro 64 Electrical Terminals for Wiring Repairs; 2002 Cadillac Seville, Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire. ENGINE/PROPULSION 4-02
46. 01-06-04-008B: Replaces 01-06-04-008A; Inaccurate or Erratic Fuel Gauge Reading (Install New Fuel Tank Sender Sensor); 2000-01 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand Am, Sunfire with plastic fuel tanks. ENGINE/PROPULSION 5-02
47. 01-06-04-008C: Replaces 01-06-04-008B; Inaccurate or Erratic Fuel Gauge Reading (Install New Fuel Tank Sender Sensor); 2000-02 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand Am, Sunfire with plastic fuel tanks. ENGINE/PROPULSION 5-02
48. 02-06-01-001A: Replaces 02-06-01-001; Drone Noise From Engine Area (Replace Accessory Drive Belt); 1999-2002 Chevrolet Cavalier, Pontiac Sunfire with 2.2L engine (VIN 4 - RPO LN2). ENGINE/PROPULSION 5-02
49. 02-06-04-009: Hesitation or Stumble on Throttle Application After Cold Start (Reprogram PCM); 1999 Chevrolet Malibu, 1999-2001 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire with 2.4L Engine (VIN T - RPO LD9). ENGINE/PROPULSION 5-02
50. 01-06-01-030A: Replaces 01-06-01-030; Higher than Expected Engine Oil Consumption (Replace Rocker Arm Cover); 1998-2001 Chevrolet Cavalier, Pontiac Sunfire, Chevrolet and GMC S Truck Model swith 4 Cylinder 2.2L Engine (VINs 4, 5 –RPOs LN2, L43). ENGINE/PROPULSION 7-02
51. 02-07-31-003: Clutch Pedal Buzz or Vibration (Replace Clutch Actuator Pipe); 2000-03 Chevrolet Cavalier, Pontiac Sunfire with Manual Transmission (RPOs M86 or M94). TRANSMISSION 7-02
52. 02-03-08-006: Revised Front Suspension Fastener Tightening Specifications; 1997-2002 Chevrolet Cavalier, Pontiac Sunfire. SUSPENSION: 8-02
53. 02-01-39-004: New PAG Oil Released; 2002 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire, with 2.2L Engine (VIN F -- RPO L61), all 2002 Passenger Cars, Trucks and Hummer H2. HVAC 10-02
54. 02-06-04-045: Revised DTC P0327; 2002 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire. Engine/Propulsion 10-02
55. 02-06-04-044: Service Engine Soon (SES) Light Illuminated, DTC P0440 Set (Replace Fuel Tank Evaporative Emissions Control System EVAP Vent Solenoid Harness); 2000-02 Chevrolet Cavalier, Pontiac Sunfire. Engine/Propulsion 10-02
56. 02-06-04-045: Revised DTC P0327; 2002 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire. Engine/Propulsion 10-02
57. 02-08-44-012: Enable or Disable Remote Keyless Entry (RKE) Radio Personalization Feature; 2000-02 Chevrolet Cavalier, Malibu, Oldsmobile Alero, Pontiac Grand Am, Sunfire. Body and Accessories 10-02
58. 02-06-04-046; Service Engine Soon Light On Intermittently and DTC P1441 Stored (Reprogram the PCM); 2002 Chevrolet Cavalier, Pontiac Grand Am with 2.2L Engine (VIN 4 -- RPO LN2). Engine/Propulsion System 11-02
59. 01-03-10-005A; replaces 01-03-10-005; Wheel Squeak (Install Wheel Cover Insulators); 2000-03 Chevrolet with 14 and 15 Inch Wheel Covers, 2000-02 Pontiac Sunfire with 14 Inch Wheel Covers. Suspension 12-02
60. 02-02-32-012: Rattle/Knock Noise When Turning While Driving Over Rough Roads (No Fix at This Time, Fix Under Development); 1999-2002 Chevrolet Cavalier, Pontiac Sunfire. Steering 1-03
61. 02-03-08-008: Rattle/Creak/Popping Type Noise from Front of Vehicle When Turning (Replace Both Front Stabilizer Shaft Insulator Brackets); 2002-03 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire with FE1 or FE2 Suspension . Suspension 2-03
63. 02-07-30-050: Engineering Changes to Valve Body, Pressure Regulator Valve, 2-3 Accumulator Valve and Bore; applicable 1995-2003 Chevrolet Cavalier, Malibu, Oldsmobile Cutlass, Alero, Pontiac Sunfire, Grand Am with 4T40E or 4T45E Transaxle (RPOs MN4 or MN5). Transmission/Transaxle 2-03
64. 02-08-43-005: New Windshield Wipe Motor Assembly; 2003 Chevrolet Cavalier, Oldsmobile Alero, Pontiac Grand Am, Sunfire Body and Accessories 3-03
65. 03-08-49-002; I/P Cluster Lens May Haze or Crack (Replace I/P Cluster Lens Only); 2003 Chevrolet Cavalier. Body and Accessories 4-03
66. 03-08-59-001: Rattle Noise from Front Center of Dash Area (Reroute/Insulate Accelerator Cable); 2002-03 Chevrolet Cavalier, Pontiac Sunfire with 2.2L Engine (VIN F -- RPO L61). Body and Accessories 5-03
67. 01-06-04-008D: 2000-2003 Cavalier, Sunfire, Grand Am, Alero, Malibu – Inaccurate Fuel Gauge. Replace sensor card for fuel gauge accuracy issue. Replace the fuel sender / pump assembly. Body and Accessories 6-03
68. 03-06-01-018: 2002-2004 L61 EcoTech 4 Cylinder Engine. Replace Cylinder Bore Liner. Engine/Propulsion System 7-03
69. Recall 03042: 2004 L61 EcoTec 4 Cylinder – 2.2L Engine Misfire, DTC P0300. Replace spark plug sets. Don’t replace PCM or ignition cassettes. Engine/Propulsion System 10-03
70. 03-08-64-011A: 2000-2004 Cavalier/Sunfire – O/S Rearview Mirror Vibration Align insulator patch and tighten nuts to specification. Don’t replace the entire mirror assembly. Body and Accessories 11-03
71. 03-07-31-005: 2000-2004 Cavalier/Sunfire -- Grinding noise when clutch pedal fully depressed (very low mileage). Replace clutch hydraulic line. Don’t replace clutch/bearing. Transmission 3-04
72. 02-07-30-039C: 2001-2003 All cars with 4T40/45E, 4T65E and 4T80E – Code P0742 Replace TCC PWM Solenoid. Don’t replace transmission, Torque converter, or valve body assembly. Transmission 4-04
73: 03-08-67-009A: 2000-2004: Cavalier/Sunfire/Alero/Grand Am – Inoperative Sunroof Module. Retime module or replace only motor. Don’t replace entire sunroof module assembly. Body and Accessories 9-04
74: 03-01-38-005B: 2003-2004 Cavalier, Sunfire – HVAC Control Head, Difficult to Adjust Mode Dial. Replace foam which, delaminated from the model door, can cause bind condition. Don’t replace HVAC control head, module or cables, unless they are damaged. Interior 2-05
75: 03-01-38-012A: 2003-2004 Cavalier, Sunfire – Noisy A/C Compress. Inspect for ground-out conditions that can cause A/C compressor noise complaints. Don’t replace A/C compressor for excessive noise without inspecting for ground-outs. Body and Accessories 5-05
76. 05-06-04-026A: 2002-2005 Cavalier, Sunfire, Grand Am, Classic – Vehicle Hesitates, No Start, Lack of Power, Low Fuel Pressure. Before replacing fuel pump module, replace fuel pump strainer using kit, P/N 88967293. Don’t replace fuel pump module. Engine/Propulsion System 8-05
(!)------------------------------------------------------------------------------(!)
***Some details on TSBs or other J-body related issues.***
2000 J-Body Instrument Cluster Lockup
The instrument cluster on some 2000 Cavalier and Sunfire models may appear to be dead, with no movement from the gauges and a nonfunctional odometer. This condition may occur when the battery has been disconnected, or if the vehicle has a dead battery and is jump-started. Do not replace the instrument cluster to correct this condition. The cluster's micro-processor resets before the crystal stabilizes, causing the processor to lockup, when
t h e re is a loss of power. This lockup condition can be corrected by removing the fuse marked "CLSTR" (circuit 1440), waiting approximately one second, then reinstalling the fuse. The fuse panel access door is on the left side of the instrument panel. Once the fuse is installed, the cluster should reset with the gauge needles vibrating at their zero positions for about two seconds. The body computer also will reset. For the 2001 model year, a power- on -reset chip will be added to the instrument cluster. 4-00
Power Window Motor Replacement
If the owner of a 1987-present Cavalier or Sunfire is concerned about a power window
motor that does not work, or has had a short service life, it may be due to an incorrect
replacement part. The original service replacement part number 12487630 was briefly superseded by a bronze-colored universal motor part number 12497971. The correct part number is 24015712 and is silver in color. 24015712 will work on both current and older Cavaliers and Sunfires. Part release number information
has been corrected.
Popping Noise While Turning
Owners of some 2002 Chevrolet Cavaliers or Pontiac Sunfires may comment that they hear a popping type noise when turning the steering wheel. This noise is most easily replicated after a short drive on uneven asphalt, then turning the vehicle left or right into a 90 degree turn. The popping noise will occur only one time per turn.
The condition may be caused by the stabilizer bar-to-suspension support brackets being out of specification. Replacement of the Stabilizer Bar Brackets is recommended to eliminate the noise associated with this condition.
The part number for the bracket is 22660396.
Revised Windshield Wiper System (TSB# 64)
A revised windshield wiper system will be installed as a running change on 2003 Chevrolet Cavalier and Pontiac Sunfire beginning in January (VIN 7 on January 2, VIN S on January 11). The 2003 Pontiac Grand Am, Chevrolet Malibu and Oldsmobile Alero will be added on February 3. Taking the most obvious first, a protective plastic sleeve is installed on the wiper blade at the factory.
Gaps in the hook clip and lever of the blade assembly have been reduced to reduce noise and chatter, and to improve winter performance.
The controller assembly now operates digitally instead of with variable voltage, providing a more reliable interval wipe.
The manufacturing process for the frame tube and transmission housing has been simplified, and it is more stable.
And finally, the new assembly weighs about 11 ounces (300 grams) less
Tip: Parts are not interchangeable between the earlier system and the new one. Consult parts catalog for the appropriate numbers.
Fuel Level Sensor
This information applies to 2000-2003 Cavalier, Sunfire, Malibu, Alero and Grand Am with an inaccurate fuel gauge level reading.
If normal diagnostics lead you to replace the fuel level sensor, here is some late-breaking news.
A new fuel level sensor is manufactured with gold contact surfaces to provide protection against sulfur and contamination in the fuel.
TIP: The previous sensor/pump module is no longer available. The fuel level sensor and the fuel pump module are available as separate replacement parts.
TIP: If you are dealing with an inaccurate gauge condition, install the sensor. If you are dealing with a fuel system performance condition, install the fuel pump module.
Fuel Level Sensor 22709333
Fuel Pump Module (excludes sensor) 88957239
Increased Steering Effort
This condition affects 2003 Chevrolet Cavalier (fig. 13), Pontiac Sunfire, Grand Am, and Oldsmobile Alero equipped with 2.2L L61 Ecotec engine (VIN Code F).
A customer may comment on increased steering effort at vehicle start up on mornings with low ambient temperatures (below 30° F, -2°C).
It may be difficult to confirm this condition, as it may be somewhat intermittent. Normal testing of the steering system (flow meter, test drive, etc.) after vehicle warm up may also be inconclusive. The cause of this condition is a priming issue with the power steering pump. The problem is not within the steering rack. The correct repair procedure is to replace the power steering pump.
Cylinder Bore Liner Replacement (L61-Ecotec) (TSB#68)
A new tool EN-45680-850 has recently been released to replace cylinder bore liners in the 2.2L Ecotec four-cylinder engine (RPO L61 VIN F or D).
Background
The cylinder block of the Ecotec engine is lost-foam cast aluminum alloy, with pressed-in centrifugally-cast grey-iron cylinder bore liners.
In production, the liners are pressed into the block, then the deck of the block and liners are machined all at the same time. The production specification calls for the liners to be flush with the block, to + 0.02 mm (0.0008 in.) above deck.
The cylinder liner is beveled at the bottom end to help guide the liner into the block bore. And the top of the liner is slightly flanged, fitting into a counter bore in the block. This ensures that the liner is properly seated when it is pressed into place.
Cylinder Damage
A cylinder bore of any engine can be damaged by a broken piston ring, a loose wrist pin or clip, or piston debris caused by detonation damage. The Ecotec is susceptible to the same kinds of hazards. In the Ecotec engine, the liners are thin-wall castings, on the order of 1.5 mm (1/16-inch) thick, so overboring is not a possibility.
Up until now, if a liner became damaged, it was necessary to replace the entire engine assembly.
With the introduction of the EN-45680 L61 (L850) Cylinder Bore Liner R&I Kit, it is now possible to replace a damaged liner. This procedure can even be done with the engine remaining in the vehicle on several vehicle product lines.
Although only the damaged liner(s) must be replaced, always inspect all of the cylinders.
Detailed instructions are included with the tool kit, and are also available in SI. These are the highlights.
Liner Removal
The cylinder head must be removed, along with the piston and rod from the affected cylinder(s). Follow SI procedures.
The fixture assembly is attached above the cylinder bore with previously-used cylinder head bolts.
TIP: Cylinder head bolts must not be reused.The fixture is installed from above, with the shoe positioned flat against the bottom of the cylinder liner.A nut on the puller is turned to pull the liner from the block.
TIP: Do not use any power tools to turn the removal tool nut, to avoid damage to the block.
Liner Installation
After inserting a replacement liner into the top of the cylinder bore, position the fixture above the cylinder bore and attach with the four used cylinder head bolts.
An installation assembly is used to press the liner into place.
TIP: Do not use any power tools to turn the arbor screw, to avoid damage to the liner.
When the liner is installed to within 1/16-inch (1.6 mm) of the block deck face, use a torque wrench to tighten the arbor to specification. When the flange of the liner seats into the counter bore of the block, a minimal portion of the liner remains above the deck surface.
Liner Trimming
The kit includes debris plugs to be installed in the affected cylinder and adjacent cylinder(s).
The service liner is very similar to the ones used in production. To complete the installation, it’s necessary to machine the top of the liner to production height specification, flush with the block deck to + 0.02 mm (0.0008 in.) above deck.
It is also necessary to avoid damage to the block deck surface. This requires proper setup of the cylinder liner trim tool.
TIP: Follow the instructions exactly to set up the cutting blades of the cylinder liner trim tool, using the set gage ring supplied.
The cylinder liner trim tool is installed to the block over the affected cylinder. An electric drill motor with specific power rating and rpm must be used to operate the trimmer. And compressed air operates the venturi vacuum that catches the metal shavings as the liner is trimmed.
If multiple cylinder liners are being replaced, move the cylinder liner trim tool and debris plugs from cylinder to cylinder as required.
Right Front Speaker Rattle
A rattle or buzz from the right front speaker on a 2000-04 Sunfire or Cavalier may be generated by the door trim panel upper extension covering the exterior mirror mount (commonly known as the shark fin) . Before replacing the speaker, verify that the shark fin is not the concern. Apply pressure to the shark fin at the forward lower corner. If the rattle diminishes, repair the concern by removing the trim panel (refer to Document 1043347). Add a foam block to the forward lower corner to dampen the low frequency vibrations. Install the trim panel and tighten the screw to 1.3 Nm or 12 lb in.
“Rotten Egg” Exhaust Odor
Three conditions are necessary for "rotten egg" or hydrogen sulfide odor to be present in exhaust gasses:
- Hot catalytic converter
- Sulfur in the fuel
- Rich air-fuel ratio, at least momentarily.
Of these three, the quantity of sulfur present in the fuel is the most variable, and most difficult to control for both a vehicle manufacturer and a customer.
High amounts of sulfur in fuel can cause not only a rotten egg odor in exhaust gasses, but also certain re-active sulfurs can corrode silver contacts in the fuel level sender, causing erroneous fuel gauge readings.
At present, there is no EPA requirement for the level of sulfur in fuel, outside of the state of California, and the ASTM (American Society for Testing and Materials) specification limit is 1000 parts per million (PPM). To put that number into perspective, the current limit for sulfur in California phase 2 gasoline requires an average of less than 30 PPM.
In 2004, the EPA will begin limiting the sulfur content in gasoline. In 2004, the EPA limit for the corporate average sulfur content will be 120 ppm, and no single gasoline can exceed 300 ppm (except for small refiner exemptions). By 2006, the corporate average will be limited to 30 ppm (the current California limit), with a maximum of 80 ppm (except for small refiner delays). California Phase 3 gasoline, which will be available next year, will have a maximum sulfur content of 15 ppm.
In the absence of an identified vehicle condition, customers can be advised to temporarily change to a premium grade brand of fuel from a major supplier such as Shell, Exxon, Texaco or Chevron. Premium fuels in general have been found to have lower sulfur levels. However, even these suppliers can be susceptible in areas where base fuels are delivered either by pipeline or from the same refinery.
TIP: Dealers should refrain from attempting repairs or replacing catalytic converters for odor complaints
Transaxle Electrical Connector (Hard Shifts)
Be on the lookout for bulletin 02-07-30-022B, which is being re-issued to include 2004 model year vehicles.The bulletin applies to numerous carlines which use the 4T65-E, 4T40-E or 4T45-E transaxles.
Some customers may comment that the SES lamp is illuminated, accompanied by extremely harsh shifts. The conditions may be caused by an intermittent connection at the transaxle 20-way connector.
The bulletin lists six potential causes:
- harness stretched tight
- terminals not fully seated
- male terminals bent
- female terminals loose
- terminals insufficiently crimped to wire
- connector not properly seated and locked
Perform an inspection and make the necessary repairs
2004 Cavalier Accessory Power Outlets
Many Cavaliers were susceptible to blowing the cigar lighter fuse when certain power accessory plugs were used in the outlet. For production, Engineering has switched from a cigar lighter housing to an Accessory Power Outlet (APO) on the instrument panel.
Cigar lighters and APOs use different electrical connectors. During the time while the electrical harness was being redesigned, Engineering created a hybrid APO. It consists of the body of a standard APO and the connector base of a cigar lighter housing.
10,500 Cavaliers were built with the hybrid APO (between VIN breakpoints 1G1JC52F947205493 and 232627). After the end breakpoint, the I/P wire harness will be using a universal connector that allows either the APO or the cigar lighter housing to be used.
TIP: They hybrid part will not be available to service. Use only the cigar lighter housing to replace the hybrid
Modular Fuel Pump Terminals
This diagnostic tip applies to modular fuel pumps on C/K pickup, S-truck, Cavalier, Sunfire and Malibu.
Before condemning a fuel pump, check the terminals in the connector on the pump module and in the wiring harness connector. If a harness terminal is spread apart, it will cause excessive resistance, which leads to overheating of the terminal.
If you discover this condition, replace the harness connector and terminals with the appropriate service pigtail, available from GM
HVAC Cables - Binding Mode Valve -- HVAC (TSB #74)
Bulletin 03-01-38-005B covers various HVAC concerns on 2003-04 Chevrolet Cavalier and Pontiac Sunfire related to mode and temperature control cables.
Be sure to refer to the bulletin for details. Here are some highlights.
Because symptoms show up as a control knob that is difficult to move, blame is often placed wrongly on the control head. The control head has not been identified as a cause of effort concerns, although the head may become damaged by forcing a knob to overcome an operating condition elsewhere.
If the foam on the HVAC mode valve (mode door) comes loose, the customer may experience difficulty in changing modes (heat, vent, or A/C) or air blows only from the upper vents.
A mode valve seal kit 89018656 is needed for this procedure.
TIP: Be sure the cable mounting tabs on the control head are intact.
Cable Conditions
The bulletin points out that a cable may bind, or may become kinked, due to:
- Improper cable routing -- Be sure routing does not cause cable housing or cam interference when the control head knob is operated.
- Improper cable clip positioning -- May have been improperly installed at assembly, or may have pulled off by forcing the control head.
- Cable interference with wiring -- Tie back wiring as necessary.
- Stuck or binding valve -- The defrost valve arm may drop off the edge of the surface and become stuck. The bulletin details how to grind the area. Foam or adhesive may interfere with operation of defrost and mode valves. The bulletin explains how to trim the material to allow free operation.
Repair Tips
Here are some general tips.
- For difficult mode valve operation, where the valve is not stuck, check the mode cable housing for interference with the cam. The cable can interfere with the cam during rotation, causing a condition of low effort, high effort then low effort again.
- If a cable is kinked or stretched, replace it.
- Cables don’t have to be replaced in pairs.
- If routing or clip position was incorrect, be sure to fully function test after making repairs.
- If a cable and clips are not damaged, the cable may be re-used.
TIP: Part number 89018237 (seal kit) is NOT required when replacing a cable.
Part Number & Description
89018243 Cable, Mode Control
89018243 Cable, Temp Control
Gold Bow Tie Emblem
Certain cleaning substances used by some pre-delivery departments can cause a discoloration of the gold bow tie appliqué on the 2004 Chevrolet Cavalier and the SSR.
A chemical intended to remove bug debris has been found to discolor the bow tie. Avoid chemicals listing oxalic acid, dehydrate tech organic acid or hydro-fluorides as an ingredient.
TIP: It is not necessary to avoid using these chemicals to clean vehicles, but BE SURE to avoid contact with the gold bow tie.
GM Brand Quality is working with the supplier to increase the durability of the parts so they are more robust to cleaning agents. Closely inspect your inventory of vehicles to determine if a potential issue exists. If you notice discoloration, stop use of the chemical agent immediately, and file a field product report.
Idle Flare or Decel Stall
This condition may affect 2002-04 vehicles with 4 cylinder 2.2L engine
(VIN F - RPO L61) (Chevrolet Malibu, Cavalier, and Classic, Oldsmobile Alero, Pontiac Grand Am and Sunfire).
Some owners may comment about an engine idle flare when the clutch is depressed. Also, some owners may comment about a low speed engine decel stall when coming to a stop.
The flare is caused by the vehicle entering stall-saver mode when the clutch is depressed. The low speed engine decel stall is produced by an interaction between the engine control software and the IAC motor.
Reprogram the PCM with the latest calibration available. The new calibration was released beginning with TIS satellite data update version 6.0 for 2004 available June 2004. As always make sure your Tech 2 is updated with the latest software version.
CD Player Concern
This condition can affect the single CD player in the following vehicles:
- Chevrolet Impala, Monte Carlo, Cavalier and Venture
- Pontiac Grand Am, Sunfire, Bonneville, Aztek, and Transport
- Oldsmobile Alero and Silhouette
A customer may comment that the CD player will not accept a CD, will not play, or will not eject a CD.
The condition may result when the gap between the insertion protection gates and the top guide plate is larger than specification. This was caused by a warped top guide, which has been corrected in production.
Exchange the audio unit, so the top guide plate can be inspected. Do not attempt to remove a stuck CD.
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