SPECIAL POLICY: ENGINE SURGE/ CHUGGLE AT HIGHWAY SPEEDS. Geo Prizm 1989

For 1990-2009 cars

# SPECIAL POLICY: ENGINE SURGE/ CHUGGLE AT HIGHWAY SPEEDS

#### Subject: ENGINE SURGE / "CHUGGLE" AT HIGHWAY SPEEDS

#### Model and Year: 1989 - 90 Geo PRIZM

General Motors has determined that certain 1989-90 Geo Prizm niodel vehicles may experience an engine surge/ "chuggle" at highway driving speeds above 45 miles per hour. This condition may be initiated by a slight "tip-in" acceleration or by a deceleration "coast" condition. The surge/"chuggle" may range from a discrete, but annoying,'bump" lasting a second or less, to a long term bucking sensation lasting for a prolonged period of time.

VEHICLES INVOLVED: Involved are certain 1989-90 Geo Prizm model vehicles built within the following VIN breakpoints and which exceed the mileage limitation of the vehicles Emission Warranty: PLANT YEAR MODEL PLAN CODE FROM THROUGH 1989 S-Car Fremont "Z" KZOOOOO1 KZOO2820 1990 S-Car Fremont "Z" LZO10001 LZO90311

SPECIAL POLICY ADJUSTMENT: This Special Policy covers the condition described above, regardless of ownership, until April 8, 1994 for vehicles which have exceeded the mileage limitation of the Emission Warranty. Correction at no charge to the customer will consist of installing a new Manifold Absolute Pressure (MAP) wiring harness connector and sensor.

NOTICE ANY VEHICLE EXPERIENCING THIS CONDITION BUT WHICH IS STILL UNDER THE MILEAGE REQUIREMENTS OF THE EMISSION WARRANTY SHOULD ALSO BE REPAIRED FOLLOWING THE PROCEDURES IN THIS BULLETIN. HOWEVER, CLAIM COVERAGE FOR THESE VEHICLES WILL BE UNDER THE STANDARD EMISSION WARRANTY. LABOR OPERATIONS FOR BOTH SITUATIONS ARE GIVEN IN THIS BULLETIN.

This "Special Policy Adjustment Bulletin" should be filed in your "Special Policy Adjustment Bulletins" binder furnished to dealers by General Motors.

REIMBURSEMENT: Customer claims for reimbursement on previously paid repairs to correct an engine surge/"chuggle" condition are to be submitted by October 8, 1993 according to the forms and instructions included in this bulletin (additional copies to be reproduced locally - the time limitation for presenting the original paid receipt may be longer depending upon the law in your state). Owners must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, and the person or entity performing the repair.

#### OWNER NOTIFICATION:

Owners will be notified of this Special Policy by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

#### PARTS INFORMATION:

Parts 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

94854832 MAP Sensor Assembly Kit 1 Includes: 1 MAP Sensor And Bracket Assembly 1 Jumper Wire Harness 1 Tie Strap

12089189 Splice Sleeves 3 (Merchandised / Package of 20)

#### SERVICE PROCEDURE:

1. Check and, if necessary, reset throttle position sensor (TPS) setting as as specified in the l989-9O Geo Prizm Service Manual (section 6E3-C2)

2. Disconnect negative (-) battery cable.

3. Disconnect electrical wire harness connector (Figure 1, 607) from manifold absolute pressure (MAP) sensor (Figure 1, 606).

4. Cut off MAP sensor wire harness connector (Figure 1, 607) directly behind connector housing.

5. Cut and remove 75mm (approx. 3 inches) from end of protective conduit around MAP sensor wire harness.

#### NOTICE: Be careful not to cut into any of wires inside conduit when cutting plastic sleeve.

6. Strip 8 to 11 mm (1/3 to 2/5 in.) of insulation from ends of wires of existing MAP sensor wire harness. Do same for wires of new jumper harness included in kit.

7. Attach (splice) jumper wire harness to MAP sensor wire harness on vehicle using the three special "crimp and seal" splice sleeves supplied in kit. These sleeves are the same type of special "sealed splice" sleeves as those supplied in Terminal Repair Kit J-38125A used for repairing SIR system wiring.

#### NOTICE: Be certain wire colors are matched before splicing wires together.

Also, the special "crimp and seal" splice sleeves should be installed using the procedure described in section 9J (page 9J-l 7) of the 1992 Geo Storm Service Manual.

8. Postion wire splices so that they are staggered and wrap all three wires together with electrician's tape.

#### NOTICE: Extend tape wrapping to 50 to 70mm (2 to 2 3/4 inches) passed ends of splices.

9. Disconnect vacuum hose to existing MAP sensor mounted on front of dash bulkhead.

10. Remove existing MAP sensor and replace it as shown in Figure 2 with new MAP sensor and new MAP sensor bracket assembly supplied in kit.

11. Reconnect vacuum hose removed in step 9.

12. Connect jumper harness connector to new MAP sensor. Snap 'rosebud" retainer on jumper harness into hole on MAP sensor bracket as shown in Figure 2.

13. Route lower portion of MAP sensor wire harness through existing clip on intake plenum runner as shown in Figure 3. Use tie strap supplied in kit to create wire loop outside of clip.

14. Reattach negative (-) battery cable.

15. Road test vehicle and verify surge no longer exists.

#### CLAIM INFORMATION:

Submit a claim with the information indicated below:

FAILED PARTS CC-FC LABOR LAB OTHER REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS

Install MAP Kit- Vehicle Over 4 94854832 SP-95 T1890 0.4 --- Emission Warranty Mileage Limitation

Install MAP Kit- Vehicle Covered 4 94854832 SP-95 T1922 0.4 --- Emission Warranty

Reimbursement For Prior Surge Repair SP-95 T1923 --- 0.2

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

Refer to the Chevrolet Claims Processing Manual for details on claim

INSTRUCTIONS

1 R.O. # & DATE The dealership should enter the repair order number and date of the reimbursement request. 2 WORK PERFORMED (MONTH, DAY) Date owner had work performed.

3 VEHICLE IDENTIFICATION # VIN involved.

4 MILEAGE Enter mileage at time of repair. (If not available, enter "O")

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation is preprinted on form.

7 & 8 SUBLET DMN Enter exact amount of reimbursement. No deductible LINE TOTAL will be taken. (Do not enter parts or labor hours on claim)

9 AUTH CODE If the amount of reimbursement approved is $300 or less, no authorization is needed. If the amount contact Chevrolet Dealer Assistance Center 1-800-CHEV-454.

10 REQUESTED Dealer Service Manager enters the amount determined REIMBURSEMENT from owner supplied invoices or paid receipts, which are covered.

11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. If the total amount exceeds $300, contact Chevrolet Dealer Assistance Center 1-800-CHEV-454.

12 740 STAMP See Item #11 to determine need for authorization.

13 DEALER REFERENCE INFORMATION Enter Document Number & Line Number on which claim was submitted

Enter Claim Memo Number and Date when claim is credited.

Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER INFORMATION Must include telephone number.

15 DEALER INFORMATION Includes Dealer Code, Deale Name Service Manager's signature and social security number. To be completed by Service Manager

16 EXPLAIN Should the dealer Service Manger determine, after review of owner's invoices/receipts, that the that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the vehicle history file. file.

17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

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.