Pontiac Sunfire 1995 2.3L DOHC Workshop Manual

pontiac :: Pontiac Sunfire L4-138 2.3L DOHC VIN
D MFI (1995)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Technical Service Bulletins > Resetting the Multi-function Alarm Module -

Revised

Alarm Module: Technical Service BulletinsResetting the Multi-function Alarm Module - Revised

FILE IN SECTION: 8 - Chassis/Body Electrical
BULLETIN NO.: 53-81-03
DATE: January, 1995

SUBJECT: Section 8A - Revised Procedure to Reset the Multi4unctlon Alarm Module

MODELS: 1995 Chevrolet Cavalier1995 Pontiac Sunfire

This bulletin provides the proper procedure to reset the multi-function alarm module for Section 8A-76: Audible Warnings - Chime. and Section 8A-114:Interior Lights of the appropriate Service Manual.

In various areas of Cell 76 and Cell 114, it is noted that to reset the multi-function alarm module, the ALARM Fuse must be removed. This is not correctand a note should be made in both cells that battery feed to the multi-function alarm module must be interrupted to perform reset function. This isaccomplished by removing and replacing the INT LAMP Fuse.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > OnStar(R) - Aftermarket Device Interference

Information

Emergency Contact Module: Technical Service BulletinsOnStar(R) - Aftermarket Device Interference Information

INFORMATION
Bulletin No.: 08-08-46-004
Date: August 14, 2008

Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services

Models:2009 and Prior GM Passenger Car and Truck (including Saturn)2009 and Prior HUMMER H2, H3 Models2009 and Prior Saab 9-7X
with OnStar(R) (RPO UE1)

This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic LinkConnector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails.

Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel EconomyAnalyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by asubscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic(OVD) e-mail.

These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requestingdata, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations.

The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of theunsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern.

When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of theOnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVDe-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnosticssection for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section iscollapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device.

Disclaimer

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10

> Electrical - MIL ON/DTC's Set By Various Control Modules

Relay Module: Customer InterestElectrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL

09-06-03-004DBulletin No.:

December 08, 2010Date:

Subject:

Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various ControlModules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant)

Models:

2011 and Prior GM Passenger Cars and Trucks

Attention:

This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain controlsensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminalsurfaces is sufficient to correct the condition.

Supercede:This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C(Section 06 - Engine/Propulsion System).

Condition

Some customers may comment on any of the following conditions:

- An intermittent no crank/no start

- Intermittent malfunction indicator lamp (MIL) illumination

- Intermittent service lamp illumination

- Intermittent service message(s) being displayed

The technician may determine that he is unable to duplicate the intermittent condition.

Cause

- Vibration

- Thermal cycling

- Poor connection/terminal retention

- Micro motion

- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent connections.
On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative.

Representative List of Control Modules and Components

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer

Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 20

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electricalcontact surfaces of the connection or connector. This may be caused by any of the following conditions:

The following is only a representative list of control modules and components that may be affected by this connection or connector condition and include every possible module or component for every vehicle. DOESNOT

- Blower Control Module

- Body Control Module (BCM)

- Communication Interface Module (CIM)

- Cooling Fan Control Module

- Electronic Brake Control Module (EBCM)

- Electronic Brake and Traction Control Module (EBTCM)

- Electronic Suspension Control (ESC) Module

- Engine Control Module (ECM)

- Heating, Ventilation and Air Conditioning (HVAC) Control Module

- HVAC Actuator

- Inflatable Restraint Sensing and Diagnostic Module (SDM)

- Any AIR BAG module

- Seatbelt Lap Anchor Pretensioner

- Seatbelt Retractor Pretensioner

- An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023

- Powertrain Control Module (PCM)

- Remote Control Door Lock Receiver (RCDLR)

- Transmission Control Module (TCM)

Correction

replace the control module, wiring or component for the following conditions: ImportantDO NOT

-

be duplicated. The condition is intermittent and cannot

-

be duplicated. The condition is present and by disconnecting and reconnecting the connector the condition can no longer

Use the following procedure to correct the conditions listed above.

1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the

control modules (refer to SI).
If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component

which may be causing the condition (refer to SI).

If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the

condition (refer to SI).

2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator

documents to locate and disconnect the affected harness connector(s) which are causing the condition.

ImportantDO NOT

apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate theconnectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin.

3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s).

4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer

Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 21

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Note

Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severecases it may be unable to be seen or identified without the use of a magnifying glass.

- DTC Diagnostic Procedure

- Circuit/System Description

- Conditions for Running the DTC

- Conditions for Setting the DTC

- Diagnostic Aids

- Circuit/System Verification

If the condition cannot be duplicated, the repair is complete. If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).

Repair Order Documentation

be documented on the repair order. Failure to do so may result in a chargeback.ImportantThe following information MUST

- Customer vehicle condition.

- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message.

- Was a DTC(s) set? If yes, specify which DTC(s) were set.

- After following the procedure contained within this bulletin, could the condition be duplicated?

If the condition duplicated, then document the affected module/component connector name and number on the repair order. was not

-

was

If the condition duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement ofa module or component, the SI Document ID Number be written on the repair order. MUST

Parts Information

Alternate Distributor For All of North America
Note

NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in thisbulletin.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does notendorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be availablefrom other sources.

Warranty Information (excluding Saab Models)

For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectriclubricant was applied to:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer

Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 22

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Warranty Information (Saab Models)

For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectriclubricant was applied to refer to the table above.

Disclaimer

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-

004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules

Relay Module: All Technical Service BulletinsElectrical - MIL ON/DTC's Set By Various Control Modules
TECHNICAL

09-06-03-004DBulletin No.:

December 08, 2010Date:

Subject:

Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various ControlModules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant)

Models:

2011 and Prior GM Passenger Cars and Trucks

Attention:

This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain controlsensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminalsurfaces is sufficient to correct the condition.

Supercede:This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C(Section 06 - Engine/Propulsion System).

Condition

Some customers may comment on any of the following conditions:

- An intermittent no crank/no start

- Intermittent malfunction indicator lamp (MIL) illumination

- Intermittent service lamp illumination

- Intermittent service message(s) being displayed
The technician may determine that he is unable to duplicate the intermittent condition.

Cause

- Vibration

- Thermal cycling

- Poor connection/terminal retention

- Micro motion

- A connector, component or wiring harness not properly secured resulting in movement
On low current signal circuits this condition may cause high resistance, resulting in intermittent connections.
On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative.

Representative List of Control Modules and Components

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 28

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electricalcontact surfaces of the connection or connector. This may be caused by any of the following conditions:

The following is only a representative list of control modules and components that may be affected by this connection or connector condition and include every possible module or component for every vehicle. DOESNOT

- Blower Control Module

- Body Control Module (BCM)

- Communication Interface Module (CIM)

- Cooling Fan Control Module

- Electronic Brake Control Module (EBCM)

- Electronic Brake and Traction Control Module (EBTCM)

- Electronic Suspension Control (ESC) Module

- Engine Control Module (ECM)

- Heating, Ventilation and Air Conditioning (HVAC) Control Module

- HVAC Actuator

- Inflatable Restraint Sensing and Diagnostic Module (SDM)

- Any AIR BAG module

- Seatbelt Lap Anchor Pretensioner

- Seatbelt Retractor Pretensioner

- An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023

- Powertrain Control Module (PCM)

- Remote Control Door Lock Receiver (RCDLR)

- Transmission Control Module (TCM)

Correction

replace the control module, wiring or component for the following conditions: ImportantDO NOT

-

be duplicated. The condition is intermittent and cannot

-

be duplicated. The condition is present and by disconnecting and reconnecting the connector the condition can no longer

Use the following procedure to correct the conditions listed above.

1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the

control modules (refer to SI).
If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component

which may be causing the condition (refer to SI).

If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the

condition (refer to SI).

2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator

documents to locate and disconnect the affected harness connector(s) which are causing the condition.

ImportantDO NOT

apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate theconnectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin.

3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s).

4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 29

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Note

Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severecases it may be unable to be seen or identified without the use of a magnifying glass.

- DTC Diagnostic Procedure

- Circuit/System Description

- Conditions for Running the DTC

- Conditions for Setting the DTC

- Diagnostic Aids

- Circuit/System Verification

If the condition cannot be duplicated, the repair is complete. If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI).

Repair Order Documentation

be documented on the repair order. Failure to do so may result in a chargeback.ImportantThe following information MUST

- Customer vehicle condition.

- Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message.

- Was a DTC(s) set? If yes, specify which DTC(s) were set.

- After following the procedure contained within this bulletin, could the condition be duplicated?

If the condition duplicated, then document the affected module/component connector name and number on the repair order. was not

-

was

If the condition duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement ofa module or component, the SI Document ID Number be written on the repair order. MUST

Parts Information

Alternate Distributor For All of North America
Note

NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in thisbulletin.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does notendorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be availablefrom other sources.

Warranty Information (excluding Saab Models)

For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectriclubricant was applied to:

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical

Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 30

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Warranty Information (Saab Models)

For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectriclubricant was applied to refer to the table above.

Disclaimer

> Relays and Modules > Relays and Modules - Body and Frame > Convertible Top Relay > Component Information > Locations

Under Body Wiring (Left Rear: Convertible)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Locations

LH Center Of Engine Compartment

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake

Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286)

Electronic Brake Control Module: All Technical Service BulletinsBrakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286)

File In Section: 5 - Brakes
Bulletin No.: 73-50-26
Date: August, 1997

Subject: ABS Light On - DTC's 46 and 86 Set(Perform Diagnostic Procedure, Replace Center ABS Motor Pinion)

Models: 1991-97 Buick Skylark1992-97 Buick Regal1994-97 Buick Century1992-96 Chevrolet Beretta, Corsica, Lumina APV1992-97 Chevrolet Cavalier, Lumina,1993-97 Chevrolet Camaro1995-97 Chevrolet Monte Carlo1997

Chevrolet Malibu, Venture

1993-97 Geo Prizm1995-97 Geo Metro1996-97 Geo Tracker1991

Oldsmobile Calais

1992-96 Oldsmobile Cutlass Ciera1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette1997

Oldsmobile Cutlass

1998 Oldsmobile Intrigue

1991-97 Pontiac Grand Am1992-94 Pontiac Sunbird1992-97 Pontiac Grand Prix, Trans Sport1993-97 Pontiac Firebird, Trans Am1995-97 Pontiac Sunfire
Condition

Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as currentor history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles).
Cause

A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded bythe EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather ishot and humid.

Important:

Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause.

Correction

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 47

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All

Technical Service Bulletins for Electronic Brake Control Module: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 48

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in forservice. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motorpinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft.
Pinion Replacement

If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a directreplacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Completemotor pack replacement is not required.
Parts Information

Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation Labor Time

H2506 Use published labor

operation time.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake

Control Module: > 535003 > May > 95 > EBCM/EBTCM 24-Way Connector - Face View Diagram

Electronic Brake Control Module: All Technical Service BulletinsEBCM/EBTCM 24-Way Connector - Face View Diagram

File in Section: 5 - Brakes
Bulletin No.: 53-50-03
Date: May 1995
SERVICE MANUAL UPDATE

Subject:Section 5E - Revised Diagram for EBCM/EBTCM 24-Way Connector Face View

Models:1995 Chevrolet Cavalier1995 Pontiac Sunfire
This bulletin revises Figure 10 and Figure 4 found in Sections 5E1 and 5E2 of the Service Manual.

The Electronic Brake Control Module (EBCM)/Electronic Brake and Traction Control Module (EBTCM) 24-way connector face view pinout numberingis incorrect. Please refer to the attached diagram when referring to the EBCM (Section 5E1, Figure 10) or EBTCM (Section 5E2, Figure 4) 24-wayconnector face view.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 73-50-26 > Aug > 97 > Brakes -

ABS Light ON, DTC 46 & 86 (C1246 & C1286)

Electronic Brake Control Module: Customer InterestBrakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286)

File In Section: 5 - Brakes
Bulletin No.: 73-50-26
Date: August, 1997

Subject: ABS Light On - DTC's 46 and 86 Set(Perform Diagnostic Procedure, Replace Center ABS Motor Pinion)

Models: 1991-97 Buick Skylark1992-97 Buick Regal1994-97 Buick Century1992-96 Chevrolet Beretta, Corsica, Lumina APV1992-97 Chevrolet Cavalier, Lumina,1993-97 Chevrolet Camaro1995-97 Chevrolet Monte Carlo1997

Chevrolet Malibu, Venture

1993-97 Geo Prizm1995-97 Geo Metro1996-97 Geo Tracker1991

Oldsmobile Calais

1992-96 Oldsmobile Cutlass Ciera1992-97 Oldsmobile Achieva, Cutlass Supreme, Silhouette1997

Oldsmobile Cutlass

1998 Oldsmobile Intrigue

1991-97 Pontiac Grand Am1992-94 Pontiac Sunbird1992-97 Pontiac Grand Prix, Trans Sport1993-97 Pontiac Firebird, Trans Am1995-97 Pontiac Sunfire
Condition

Some owners may comment that the ABS light is on with Diagnostic Trouble Codes (DTC's) 46 and 86 set (rear ABS channel will not move) as currentor history. (DTC's 46 and 86 will be displayed as C1246 and C1286 on 1997 and 1998 model year vehicles).
Cause

A condition exists where the ABS motor pack gear (pinion) will bind on the motor armature shaft causing the motor not to move when commanded bythe EBCM. This condition is aggravated by light corrosion between the pinion and shaft. Therefore, it may occur more frequently when the weather ishot and humid.

Important:

Other EBCM and ABS motor pack concerns can also cause this condition, but they are not as common as the above cause.

Correction

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Customer Interest: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 58

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins >

Customer Interest: > 73-50-26 > Aug > 97 > Brakes - ABS Light ON, DTC 46 & 86 (C1246 & C1286) > Page 59

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Follow the included procedure (Attachments 1 and 2) for diagnosis. This condition may correct itself before the owner is able to bring the vehicle in forservice. Therefore, if DTC 46 is set in history, and is not currently setting, the included procedure will instruct you to replace the center ABS motorpinion. The new pinion has a Teflon insert which reduces friction between the pinion and motor armature shaft.
Pinion Replacement

If the included procedure instructs you to replace the center ABS motor pinion, use P/N 18029776. Please note that the new pinion is a directreplacement part which requires no modifications to the motor shaft. Follow the pinion replacement procedure included with the new pinion. Completemotor pack replacement is not required.
Parts Information

Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation Labor Time

H2506 Use published labor

operation time.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Electronic Brake Control

Module: > 535003 > May > 95 > EBCM/EBTCM 24-Way Connector - Face View Diagram

Electronic Brake Control Module: All Technical Service BulletinsEBCM/EBTCM 24-Way Connector - Face View Diagram

File in Section: 5 - Brakes
Bulletin No.: 53-50-03
Date: May 1995
SERVICE MANUAL UPDATE

Subject:Section 5E - Revised Diagram for EBCM/EBTCM 24-Way Connector Face View

Models:1995 Chevrolet Cavalier1995 Pontiac Sunfire
This bulletin revises Figure 10 and Figure 4 found in Sections 5E1 and 5E2 of the Service Manual.

The Electronic Brake Control Module (EBCM)/Electronic Brake and Traction Control Module (EBTCM) 24-way connector face view pinout numberingis incorrect. Please refer to the attached diagram when referring to the EBCM (Section 5E1, Figure 10) or EBTCM (Section 5E2, Figure 4) 24-wayconnector face view.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 65

LH Lower I/P

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Harness Connector

Electronic Brake Control Module (EBCM)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Harness Connector > Page 68

Electronic Brake Control Module: DiagramsPinout Description

Electronic Brake Control Module (EBCM): C1

Electronic Brake Control Module: C3

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Harness Connector >

Page 69

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Electronic Brake Control Module (EBCM): C2 (With Enhanced Traction System (Part 1 Of 2)

Electronic Brake Control Module (EBCM): C2 (With Enhanced Traction System (Part 2 Of 2)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Harness Connector >

Page 70

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Electronic Brake Control Module: C2 (Without Enhanced Traction System

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 71

Electronic Brake Control Module: Description and Operation
DESCRIPTION

The ABS system is controlled by a microprocessor based Electronic Brake Control Module (EBCM). Inputs to the system include four wheelspeed sensors, brakes, ignition switch and unswitched battery voltage. Outputs include three bi-directional motor controls, three lamp controls, twosolenoid controls and the system enable relay. A serial data line, located in terminal 9 of the Data Link Connector (DLC), is provided for servicediagnostic tools and assembly plant testing.

The EBCM monitors the speed of each wheel. If any wheel begins to approach lock-up and the brake switch is on, the EBCM controls the motorsand solenoids to reduce brake pressure to the wheel approaching lock-up. Once the wheel regains traction, brake pressure is increased until wheelbegins to approach lock-up. This cycle repeats until either vehicle comes to a stop, the brake is released or no wheels approach lock-up.Additionally, the EBCM monitors itself, each input and each output for proper operation. If any system fault is detected, the EBCM will store aDTC in nonvolatile memory.

On a EBTCM, the ABS portion of the module operates the same as a EBCM. A EBTCM is used if the vehicle is equipped with either theEnhanced Traction System (ETS) or Traction Control System (TCS). The ETS or TCS portion of the EBTCM monitors wheel spin slip throughthe drive wheels speed sensors. If the wheels begin to slip, the EBTCM determines the desired wheel torque needed to minimize wheel slip. Thisinformation is sent to the PCM through the Serial data link. On models equipped w/ETS, the PCM controls engine torque by ignition retard andtransmission shifts. On models equipped w/TCS, the PCM controls engine torque by ignition retard, transmission shifts and applies brakes severaltimes until the vehicle regains traction. Once the vehicle regains traction, brake pressure is decreased and engine torque reduction is no longerrequested. This cycle repeats until traction control is no longer necessary.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Page 72

Electronic Brake Control Module: Service and Repair

Fig. 800 EBCM Assembly Removal.

Fig.800

1. Disconnect EBCM electrical connectors, .2. Remove ECU to dash panel attaching screws, then the ECU from dash panel.3. Reverse procedure to install, noting the following:

a. Ensure plastic grommets, if equipped, are located properly.b. Bleed brake system as described under . See: Brakes and Traction Control/Brake BleedingBrake System Bleed

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Technical Service Bulletins > EBCM/EBTCM 24-Way Connector - Face View Diagram

Traction Control Module: Technical Service BulletinsEBCM/EBTCM 24-Way Connector - Face View Diagram

File in Section: 5 - Brakes
Bulletin No.: 53-50-03
Date: May 1995
SERVICE MANUAL UPDATE

Subject:Section 5E - Revised Diagram for EBCM/EBTCM 24-Way Connector Face View

Models:1995 Chevrolet Cavalier1995 Pontiac Sunfire
This bulletin revises Figure 10 and Figure 4 found in Sections 5E1 and 5E2 of the Service Manual.

The Electronic Brake Control Module (EBCM)/Electronic Brake and Traction Control Module (EBTCM) 24-way connector face view pinout numberingis incorrect. Please refer to the attached diagram when referring to the EBCM (Section 5E1, Figure 10) or EBTCM (Section 5E2, Figure 4) 24-wayconnector face view.

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Module: > 439014 > Jan > 95

> Two-Way Radios - Poor Performance

Cruise Control Module: All Technical Service BulletinsTwo-Way Radios - Poor Performance

File In Section: 9 - Accessories
Bulletin No.: 43-90-14
Date: January, 1995

Subject:Stepper Motor Cruise Radio Frequency Interference (RFI) with Low Land Mobile Band Radios (Replace Module)

Models:1995 Buick Skylark1995 Chevrolet Beretta, Cavalier, Corsica 1995 Oldsmobile Achieva1995 Pontiac Grand Am, Sunfire(Fleet vehicles only - see below for complete list)

ConditionSome fleet customers may comment on poor performing two-way radios.

CauseRadio frequency emissions are produced by the Stepper II cruise control module when the vehicle ignition is on. The emissions are in the 30 - 50 MHzband, which is referred to as the Low Land Mobile Band Radio. This band is used by businesses and government agencies for communication usingtwo-way radios which are installed as after market options.

This interference reduces the audio quality of the reception in the vehicle and also reduces the range at which the vehicle can receive communications.The typical land mobile user in a vehicle can communicate with a base station at a maximum range of approximately 65 miles with no interference.

The chart illustrates the effects for each platform:

CorrectionA cruise control module, P/N 25162818, has been designed that reduces interference with the Low Land Mobile Band Radios. Fleet vehicles with thenew cruise control module may be ordered on a limited basis until January, 1995. After January, 1995, the revised cruise control module will be installedin all vehicles intended to be built with the cruise control option (K34).
Parts Information

Parts are currently available from GMSPO.
Warranty Information

The fleet vehicles that will be affected by the Stepper II module are: Forestry/Conservation, government (local, state and federal) petroleum, firedepartments, and taxies. This condition does not affect rental fleets or any other fleet vehicle not mentioned.
For vehicles repaired under warranty, use:

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Module: > 439014 > Jan > 95 > Two-Way

Radios - Poor Performance

Cruise Control Module: Customer InterestTwo-Way Radios - Poor Performance

File In Section: 9 - Accessories
Bulletin No.: 43-90-14
Date: January, 1995

Subject:Stepper Motor Cruise Radio Frequency Interference (RFI) with Low Land Mobile Band Radios (Replace Module)

Models:1995 Buick Skylark1995 Chevrolet Beretta, Cavalier, Corsica 1995 Oldsmobile Achieva1995 Pontiac Grand Am, Sunfire(Fleet vehicles only - see below for complete list)

ConditionSome fleet customers may comment on poor performing two-way radios.

CauseRadio frequency emissions are produced by the Stepper II cruise control module when the vehicle ignition is on. The emissions are in the 30 - 50 MHzband, which is referred to as the Low Land Mobile Band Radio. This band is used by businesses and government agencies for communication usingtwo-way radios which are installed as after market options.

This interference reduces the audio quality of the reception in the vehicle and also reduces the range at which the vehicle can receive communications.The typical land mobile user in a vehicle can communicate with a base station at a maximum range of approximately 65 miles with no interference.

The chart illustrates the effects for each platform:

CorrectionA cruise control module, P/N 25162818, has been designed that reduces interference with the Low Land Mobile Band Radios. Fleet vehicles with thenew cruise control module may be ordered on a limited basis until January, 1995. After January, 1995, the revised cruise control module will be installedin all vehicles intended to be built with the cruise control option (K34).
Parts Information

Parts are currently available from GMSPO.
Warranty Information

The fleet vehicles that will be affected by the Stepper II module are: Forestry/Conservation, government (local, state and federal) petroleum, firedepartments, and taxies. This condition does not affect rental fleets or any other fleet vehicle not mentioned.
For vehicles repaired under warranty, use:

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Technical Service Bulletins > Page 91

LH Rear Of Engine Compartment (2.3L Shown, 2.2L Similar)

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Technical Service Bulletins > Page 92

Cruise Control Module: Diagrams

Cruise Control Module (Part 1 Of 2)

Cruise Control Module (Part 2 Of 2)

Cruise Control Module

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Technical Service Bulletins > Page 93

Cruise Control Module: Description and Operation
OPERATION

The module will interpret the position of the servo, the position of the control switches and the output of the speed sensor. In response to these inputs,the module electrically signals the opening or closing of the vent and vacuum solenoid valves in the servo.

The module is mounted on the dash support bracket at the right side of the steering column, but is integral with the ECM on some models with certainengines.

> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams

Blower Motor Module

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamp (DRL) Relay

Daytime Running Lamp Relay: LocationsDaytime Running Lamp (DRL) Relay
Daytime Running Lamp (DRL) Relay Location Diagram

Rear Of Front Impact Bar

Back of front impact bar.

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Daytime Running Lamp (DRL) Relay > Page 103

Rear Of Front Impact Bar

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 104

Daytime Running Light Relay

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay

Fog/Driving Lamp Relay: LocationsFog Lamp Relay

Rear Of Front Impact Bar

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 109

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

Rear Of Front Impact Bar

> Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Fog Lamp Relay > Page 110

Rear Of Front Impact Bar

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

LH Lower I/P

> Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Component Locations

Lamp Control Module: Component Locations

LH LOWER I/P

> Relays and Modules > Relays and Modules - Lighting and Horns > Lamp Control Module > Component Information > Locations > Component Locations > Page 118

LH Lower I/P

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations

Relay Box: Locations

LH Front Of Engine Compartment

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 123

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

LH Center Of Engine Compartment

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 124

Relay Box: Application and ID

Front View Of Engine Compartment Fuse/Relay Center

Front View Of Engine Compartment Fuse/Relay Center

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer

Interest: > 83-65-39A > Apr > 98 > Service Engine Now Light - On or A No Start Condition

Engine Control Module: Customer InterestService Engine Now Light - On or A No Start Condition

File In Section: 6E Engine Fuel & Emission
Bulletin No.: 83-65-39A
Date: April, 1998

Subject:Service Engine Now Light On or a No-Start Condition (Remove PCM and Seal with Silicone Sealer)

Models:1995-96 Chevrolet Cavalier1995-96 Pontiac Sunfire

This bulletin is being revised to add the Canadian Part Number. Please discard Corporate Bulletin Number 83-65-39 (Section 6E - Engine Fuel &Emission).
Condition

Some owners may comment that their Service Engine Now light is On or that the vehicle will not start.
Cause
Condition may be due to water leaking into the PCM.
Correction

1. Remove the PCM following the procedure in the 1995-96 J-Car Service Manual.

2. Thoroughly clean the PCM flange with a wire brush.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Customer Interest: > 83-65-39A > Apr > 98 > Service Engine Now Light - On or A No Start Condition > Page 135

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

3.

Apply GE Goodwrench RTV Silicone Sealer (P/N 01052915 US, P/N 12346286 - Canada) to the entire sealing area and case joint of the PCM.(See arrows in Figure 1).

4. Apply GE Goodwrench RTV Silicone Sealer (P/N 01052915 - US, P/N 12346286 - Canada) to the access cover when applicable.

5. Allow to set up and reinstall the PCM following the procedure in the 1995-96 J-Car Service Manual.

6. If the vehicle requires a new or remanufactured PCM, this procedure must be performed before the new PCM is installed!
Parts Information
P/N Description

01052915 (US) GE Goodwrench RTV

12346286 (Canada) Silicone Sealer
Parts are currently available from GMSPO.

Warranty InformationFor vehicles repaired under warranty, use the table:
Labor Operation Labor Time

J6360 0.8 hr

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer

Interest: > 83-65-39 > Mar > 98 > Service Engine Now Light - On or A No-Start Condition

Engine Control Module: Customer InterestService Engine Now Light - On or A No-Start Condition

File In Section: 6E - Engine Fuel & Emission
Bulletin No.: 83-65-39
Date: March, 1998

Subject:Service Engine Now Light On or a No Start Condition (Remove PCM and Seal with Silicone Sealer)

Models:1995-96 Chevrolet Cavalier1995-96 Pontiac Sunfire

ConditionSome owners may comment that their Service Engine Now light is On or that the vehicle will not start.

CauseCondition may be due to water leaking into the PCM.
Correction

1. Remove the PCM following the procedure in the 1995-96 J-Car Service Manual.

2. Thoroughly clean the PCM flange with a wire brush.

3. Apply GE Goodwrench RTV Silicone Sealer (P/N 01052915) to the entire sealing area and case joint of the PCM. (See arrows in Figure 1).

4. Apply GE Goodwrench RTV Silicone Sealer (P/N 01052915) to the access cover when applicable.

5. Allow to set up and reinstall the PCM following the procedure in the 1995-96 J-Car Service Manual.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Technical Service Bulletins > Customer Interest: > 83-65-39 > Mar > 98 > Service Engine Now Light - On or A No-Start Condition > Page 140

Sunfire L4-138 2.3L DOHC VIN D MFI (1995)

6. If the vehicle requires a new or remanufactured PCM, this procedure must be performed before the new PCM is installed!
Parts Information

P/N Description
01052915 GE Goodwrench RTV Silicone Sealer
Parts are currently available from GMSPO.
Warranty Information

For vehicles repaired under warranty, use:
Labor Operation Labor Time
J6360 0.8 hr