CAMPAIGN:EMISS. NONCOMPLIANCE NON-TURBO 1.5 ENGINE. Geo Spectrum 1987

For 1990-2009 cars

# CAMPAIGN:EMISS. NONCOMPLIANCE NON-TURBO 1.5 ENGINE

#### Subject: PRODUCT EMISSION CAMPAIGN 87Cl9 (a) - EMISSION NONCOMPLIANCE

--- REISSUE ---

#### Model and Year: 1987 CHEVROLET SPECTRUM WITH 1.5L NON-TURBO ENGINE (VIN CODE "7" - RPO LC5) (FEDERAL EMISSIONS ONLY)

#### To: All Chevrolet Dealers

# THIS BULLETIN CANCELS AND SUPERSEDES CAMPAIGN BULLETIN 87Cl9 ISSUED NOVEMBER, 1991. SERVICE PROCEDURE AND CLAIM INFORMATION SECTIONS HAVE BEEN REVISED. SPECIFICALLY, INFORMATION HAS BEEN ADDED FOR REPLACEMENT OF THE EXHAUST MANIFOLD FOR CASES IN WHICH DAMAGE OCCURS AS A RESULT OF OXYGEN SENSOR REMOVAL. ALL COPIES OF THE ORIGINAL BULLETIN SHOULD BE DESTROYED. REVISED INFORMATION IS SHOWN IN BOLD TYPE AND DENOTED WITH AN #.

DEALERS ARE TO CONTACT ALL OWNERS PREVIOUSLY DEFERRED FROM SCHEDULING AN APPOINTMENT TO HAVE THIS RECALL PERFORMED AS A RESULT OF DCS ADMINISTRATIVE MESSAGE 01-014 (JANUARY 16, 1992).

General Motors and the Environmental Protection Agency have determined that certain 1987 Chevrolet Spectrums equipped with 1.5L non-turbo engines (VIN code "7" - RPO LC5) might exceed Federal Emission Standards. As a result, these engines might fail state mandated emissions tests.

To correct this condition, involved vehicles will have a new service PROM installed. Also, the oxygen sensor will be checked for proper operation.

#### VEHICLES INVOLVED

Involved are certain 1987 Chevrolet Spectrums equipped with 1.5L non-turbo engines (VIN code "7" - RPO LC5) built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1987 R-Car Fujisawa 11811 H8402045 H8491860

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 were furnished to involved dealers with the original 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 have been notified of this campaign on their vehicles by Chevrolet Motor 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 new or 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 new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. DEALERS ARE ALSO TO CONTACT ALL OWNERS PREVIOUSLY DEFERRED FROM SCHEDULING AN APPOINTMENT TO HAVE THIS RECALL PERFORMED AS A RESULT OF DCS ADMINISTRATIVE MESSAGE 01-014 (JANUARY 16; 1992).

# PARTS INFORMATION ------------------- Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Quantity/ Part Number Description Vehicle ----------- ----------- --------- 16163830 Service PROM - Manual Trans. 1

16163832 Service PROM - Automatic Trans. 1

# DENOTES CHANGE

Quantity/ Part Number Description Vehicle ----------- ----------- --------- 25105107 Oxygen Sensor As Required 94401273 Exhaust Manifold As Required 94250974 Exhaust Manifold Gasket As Required 94259935 Converter-To-Manifold Gasket (Notchback) As Required 94324194 Converter-To-Manifold Gasket (Hatchback) As Required

To ensure parts availability upon initial owner request for vehicle correction, dealers are encouraged to have parts in stock before owner appointments for repair. It is estimated that approximately 65% of owners on the original VIN computer listing will seek recall repair. However, be advised that an oxygen sensor will not be required for all vehicles.

#### SERVICE PROCEDURE

1. Remove kick pad.

2. Remove ECM and replace PROM with new service PROM.

3. Reinstall ECM and kick pad.

4. Start engine and run until operating temperature is reached.

5. Turn ignition switch to "off".

6. Connect TK00000 Tech I Diagnostic Computer to ALDL connector.

7. Start engine and check idle speed. Record idle speed on work-order for later reference.

8. Turn ignition switch to "off".

9. Disconnect tach filter connector. This should force duty signal to 10% (full rich).

10. Start engine and measure oxygen sensor output voltage. Depending on idle speed recorded in Step 7 perform appropriate procedure below:

o If idle in Step 7 was equal to or less than 950 RPM (Manual Transaxle) or 1200 RPM (Automatic Transaxle):

- And, if output voltage is equal to or greater than 550 mV (Manual Transaxle) or, 650 mV (Automatic Transaxle) go to Step 13.

- Or, if output voltage is less than 550 mV (Manual Transaxle) or 650 mV (Automatic Transaxle) go to Step 11.

o If idle in Step 7 was greater than 950 RPM (Manual Transaxle) or 1200 RPM (Automatic Transaxle):

- And, if output voltage is equal to or greater than 600 mV (Manual Transaxle) or 700 Mv (Automatic Transaxle) turn ignition switch to "off" and go to Step 13.

- Or, if output voltage is less than 600 mV (Manual Transaxle) or 700 mV (Automatic Transaxle) go to Step 11.

11. Turn ignition switch to "off".

# 12. Inspect wiring between oxygen sensor and ECM for opens or shorts; repair as required. If repair to wiring is made, repeat Step 10.

If wiring has no opens or shorts, replace oxygen sensor by the following procedure:

# a. Bring engine to normal operating temperature.

# b. Apply penetrating oil or equivalent lubricant to oxygen sensor thread area and wait until absorbed.

# c. Disconnect oxygen sensor electrical connector.

# d. Remove heat tube and heat shield.

# e. By using about an 8 inch punch or chisel, tap oxygen sensor in hex area with hammer to loosen oxygen sensor (see Figure on page 5). Do not use an impact wrench. Take great care not to strip threads.

# f. Unscrew oxygen sensor after it is loose.

# g. If damage occurs to manifold when removing oxygen sensor, replace manifold as follows:

# 1g) Disconnect battery ground cable.

# 2g) Raise Vehicle.

# 3g) Disconnect exhaust pipe bracket at block.

# 4g) Disconnect exhaust pipe at manifold.

# 5g) Lower vehicle.

# 6g) Remove exhaust manifold and install new manifold.

# DENOTES CHANGE

#12. (Con't)

# 7g) Raise vehicle.

# 8g) Connect exhaust pipe at manifold.

# 9g) Connect exhaust pipe bracket at block.

# 10g) Lower vehicle.

# 11g) Reconnect battery ground cable.

# h. Install and secure new oxygen sensor to exhaust manifold.

# i. Install and secure heat shield and heat tube.

# j. Connect oxygen sensor electrical connector.

# k. Bring engine to operating temperature and retest (steps 6 through 11.

# DENOTES CHANGE

13. Reconnect tach filter connector disconnected in Step 9.

14. Disconnect TKOOOOO Tech 1 Diagnostic computer from ALDL connector.

15. Install Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected 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 and the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

# CLAIM INFORMATION ------------------- Submit a Product Campaign Claim with the information indicated below:

* FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW 0P HRS HRS ------------------------------------------------------------------------------ Replace PROM Oxygen Sensor Not 1 16163830 SK-00 ** V6330 0.4 0.1 Replaced

Replace PROM and Oxygen Sensor - 2 25105107 SK-00 ** V6331 0.7 0.1 No Damage To Exhaust Manifold

Replace PROM and Oxygen Sensor - Exhaust Manifold 5 94401273 SK-00 ** V6332 1.4 0.1 Replaced Due To Damage

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Chevrolet Spectrum owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors and the Environmental Protection Agency have determined that certain 1987 Chevrolet Spectrums equipped with 1.5L non-turbo engines might exceed federal emission standards. As a result, these engines might fail state mandated emissions tests.

WHAT WE WILL DO

To correct this condition, involved vehicles will have a new service computer chip installed. Also, the oxygen sensor will be checked for proper operation. This service will be provided for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service correction is approximately 1/2 hour (30 minutes) . Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Should your dealer not schedule a service date within a reasonable time, you should contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

If your dealer and the Customer Assistance Center are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturer's Operations Division (EN-340F), United States Environmental Protection Agency, 401 M Street. S.W., Washington, D.C. 20460.

To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if this recall work is not accomplished. 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.