Electrical - Connectors May Cause A Driveability Concern
Bulletin92-6E-22
Date
Sept.'92
Ref. No.
92-270-6E
Corp. Ref. No.
276401
SUBJECT:
VARIOUS DRIVEABILITY CONDITIONS (REPAIR OVERSIZED TERMINALS)
MODELS AFFECTED:
1992 ROADMASTER, ROADMASTER ESTATE WAGON, RIVIERA AND SKYLARK MODELS
CONDITION:
SYMPTOMS CHART
Some owners of the vehicles listed may experience various driveability conditions such as reduced fuel economy, SES light, runs rough, misses, etc. (specific concerns are described in this bulletin). If diagnosis indicates a need to replace any engine control system components (example, ECM or sensors), check suspect connector terminals and repair if necessary prior to replacing the control system component.
CAUSE:
The condition may be a result of intermittent or open circuits caused by insufficient contact between the ECM harness female terminal and the mating ECM male pin. Some of the 12089649 micro-pack 100 series female terminals (formerly P/N 12020757) could have an oversized contact area condition.
NOTE:
Either terminal part number may be used in repair.
VIN BREAKPOINTS:
Suspect vehicle VIN breakpoints are listed.
CORRECTION:
1. To check for an oversize female terminal, use a # 62* drill bit (.038 inches, .965 mm) and place a mark 1/2 inch up from the bottom of the shank of the drill bit. Place a flag made from tape at the mark on the drill (see Figure 1).
2. Remove connector from ECM and hold connector vertically up.
3. Place shank of # 62* drill bit (.038 inches, .965 mm) in connector cavity of suspect terminal. Do not push on drill (see Figure 2).
4. Repair any terminal allowing drill bit to fall unassisted to the flag on a drill bit. Any terminals having resistance or drag or not allowing drill to enter terminal are okay and do not need repair. Repair any oversized terminal as described in steps 5 through 8.
5. Remove the TPA (terminal position assurance) from the connector.
6. Remove the terminal from the connector using terminal removal tool GM 12031876-1 (Kent-Moore Tool No. J 38125-A).
7. With a pair of small needle nose pliers, resize the contact area of the terminal as shown in Figure 3.
8. To verify the terminal has been adequately sized, insert a # 63* drill bit (.037 inches, .940 mm) into the contact area as shown in Figure 4. If resistance can be felt against the bit in the resized area, resizing is complete. If no resistance is felt, repeat steps 7 and 8.
9. Raise the terminal lock tang (Figure 4) so the terminal can be properly held in the connector.
10. Reinsert the terminal into the proper connector cavity.
11. Reinsert the TPA into the connector.
12. If the terminal becomes severely damaged by using this method, replace the terminal using established terminal replacement procedures.
13. Reinstall harness to ECM and perform any required relearn procedure prior to continuing diagnosis.
* NOTICE:
Measure drill to ensure drill is of proper diameter. A larger sized drill will damage a good terminal.
WARRANTY INFORMATION:
Use applicable labor operation and time allowances.