Product Safety - Ignition Circuit Thermal Events

THIS BULLETIN SUPERSEDES RECALL BULLETIN 02008A, ISSUED MAY 2002. PLEASE DISCARD ALL COPIES OF 02008A. THE PARTS TABLE, SERVICE PROCEDURE AND CLAIM TABLE HAVE BEEN REVISED TO ADDRESS CORROSION OF THE STARTER SOLENOID "S" TERMINAL STUD.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1995-1997 Chevrolet Cavalier and Pontiac Sunfire model cars, and 1996-1997 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model cars. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car which could injure occupants of the car or cause damage to adjoining structures.

Dealers are to install a relay kit and verify that the vehicle will start with a properly charged battery in good operating condition (adequate reserve capacity, or cold cranking amps).

Involved are certain 1995-1997 Chevrolet Cavalier and Pontiac Sunfire model cars, and 1996-1997 Buick Skylark, Oldsmobile Achieva and Pontiac Grand Am model cars built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC Only) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this recall.

Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: It is estimated that only 5% of involved vehicles will require ignition switch and tilt lever replacement. Please order parts accordingly.

1. Open the hood.
2. Check the battery state of health using J 4200 Midtronics Digital Battery Tester or suitable equivalent. If the tester displays "Replace Battery", attach a battery charger to the battery while performing this repair, as the test at the end will require cranking/starting the engine six times in succession. A low battery state of charge may affect the outcome of the test.

Important: If the battery fails the test (does not have sufficient reserve capacity or cold cranking amps required), the customer should be advised that the battery is not functioning properly and should be replaced. The customer should be informed that battery replacement is not covered under this recall, and that a replacement battery may be purchased from the dealership of another source.

3. Disconnect the negative battery cable.

Caution: The oil filter, exhaust manifold and exhaust pipe may be hot. Use care to avoid personal injury.

Refer to the appropriate procedure based on the model and engine.

N car - Achieva/Grand Am/Skylark with 3.1L V6 Engine (VIN Code M)

1. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit.
2. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and the shorter hex head bolt (with the washer) included in the kit.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

3. Locate the short black wire with a ring terminal on one end from the harness kit.
4. Using the longer hex head bolt (without the washer) included in the kit, attach the ring terminal to the weld nut located on the top surface of the upper radiator support bar just to the left (driver side) of the air bag support bracket.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

5. Route the new wiring harness down to the starter motor. On vehicles with automatic transmissions, fasten the harness to the cooler lines using the clips on the harness.
6. Raise the vehicle on a suitable hoist.
7. Remove the nut from the starter solenoid "B" terminal and remove all wires and the positive battery cable from the terminal.
8. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid.

•	If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 16 and remove the nut. Do NOT perform Steps 9-15 if the stud and nut are in good condition.

•	If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 9 of this procedure. Steps 9-15 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.

9. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal.
10. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
11. Using an appropriate crimping tool, install one end of the butt connector, P/N 12089191, on the short purple wire.
12. Using wire cutters, cut the small ring off the end of the red wire on the service harness kit.
13. Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
14. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire.
15. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you have just completed Steps 9-15, proceed to Step 18. Do not perform Steps 16-17. If you did NOT perform Steps 9-15, proceed to Step 16.

16. Remove the nut from the starter solenoid "S" terminal and remove all wires from the solenoid terminal.
17. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
18. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit.
19. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
20. Install and crimp the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly.
21. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you performed Steps 9-15 earlier, proceed to the next IMPORTANT statement prior to Step 24. Do not perform Steps 22-23. If you did NOT perform Steps 9-15 earlier, proceed to Step 22.

22. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
23. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut and

Tighten
Tighten the nut to 2.5 N·m(22 lb in).

Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.

24. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
25. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
26. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
27. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.

Tighten
Tighten the nut to 11 N·m (8 lb ft).

28. Lower the vehicle.
29. Reinstall the negative battery cable to the battery.

Tighten
Tighten the bolt to 116 N·m (12 lb ft).

Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

30. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.

•	If the starter cranks the engine 6 times in a row, proceed to the next step.

•	If the starter will NOT crank the engine, skip to Procedure A for N car Achieva/Grand Am/Skylark.

31. Install the GM Recall Identification Label.

N car Achieva/Grand Am/Skylark with 2.4L Engine (VIN Code T)

1. Remove the two 10mm hex head bolts that secure the air cleaner outlet resonator to the throttle body.
2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct.
3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing.
4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body.
5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body.



6. Locate the round hole located in the small depressed area in the back side of the radiator support upper bar just to the right (passenger side) of the air bag sensor mounting bracket and install the J-nut included in the harness kit.
7. Attach the relay bracket (1) on the harness kit to the radiator tie bar (2) using the J-nut previously installed and hex head bolt included in the kit.

Tighten
Tighten the screw to 10 N·m (89 lb in).

8. On the harness kit, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
9. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
10. Route the new wiring harness down to the starter motor.
11. Remove the top starter bolt.
12. Raise the vehicle on a suitable hoist.
13. Remove the oil filter.
14. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove that brace.
15. Remove the bottom starter bolt and remove the starter.
16. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
17. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid.

•	If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 25 and remove the nut. Do NOT perform Steps 18-24 if the stud and nut are in good condition.

•	If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 18 of this procedure. Steps 18-20 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.

18. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal.
19. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
20. Using an appropriate crimping tool, install one end of the butt connector, P/N 12089191, on the short purple wire.
21. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
22. Strip back the insulation about 6.35 mm (1/4 in) on the red wire.
23. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire.
24. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you have just completed Steps 18-24, proceed to Step 27. Do NOT perform Steps 25-26. If you did NOT perform Steps 18-24, proceed to Step 25.

25. Remove the nut from the starter solenoid "S" terminal and removal all wires from the terminal.
26. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
27. Strip the insulation back about 6.35 mm (1/4 in) on the purple wire of the vehicle wiring harness.
28. Using an appropriate crimping tool install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly.
29. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you performed Steps 18-24 earlier, proceed to the next IMPORTANT statement prior to Step 32. Do not perform Steps 30-31. If you did NOT perform Steps 18-24 earlier, proceed to Step 30.

30. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
31. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut.

Tighten
Tighten the nut to 2.5 N·m (22 lb in).

Important: In the next steps, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.

32. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
33. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
34. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
35. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.

Tighten
Tighten the nut to 11 N·m (8 lb ft).




36. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor.
37. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall it in the starter.

Tighten
Tighten to 9 N·m (79 lb in).

38. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time.
39. Lower the vehicle.
40. Install the upper starter bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

41. Raise the vehicle.
42. Tighten the lower starter bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

43. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold.

Tighten

•	Tighten the two bolts attaching the brace to the intake manifold to 24 N·m (18 lb ft).

•	Tighten the two bolts to the engine block to 26 N·m (19 lb ft).

44. Install a new oil filter.
45. Lower the vehicle.
46. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator.
47. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator.
48. Install the air cleaner outlet resonator on the throttle body.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

49. Connect the air cleaner outlet duct to the air cleaner housing.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

50. Connect the electrical connector to the sensor in the air cleaner outlet duct.
51. Install the two 10mm hex head bolts that secure the air cleaner outlet resonator.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

52. Reinstall the negative battery cable to the battery.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

53. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.

•	If the starter cranks the engine 6 times in a row, proceed to the next step.

•	If the starter will NOT crank the engine, skip to Procedure A for Achieva/Grand Am/Skylark

54. Check the engine oil level and add as necessary.
55. Install the GM Recall Identification Label.

N car Achieva/Grand Am/Skylark -- PROCEDURE A (all engines)

1. Remove the fuse panel trim plate from the Instrument Panel (I/P) and remove the 15-amp AIR BAG fuse.
2. Remove the left side dash lower insulation panel.
3. Remove the Connector Position Assurance (CPA) from the yellow air bag connector located at the base of the steering column and disconnect the connector.
4. Remove the left side knee bolster trim panel.
5. If equipped, remove the tilt steering column lever.
6. Remove the bezel around the key lock cylinder.
7. Remove the screws that hold the steering column trim in place.
8. Remove both halves of the steering column trim.
9. Disconnect the wiring from the ignition switch.



10. Remove the two screws (2) holding the ignition switch (3) to the steering column (1). Remove the ignition switch from the steering column.

Notice: The ignition switch mounting screws and the screws that secure the upper and lower halves of the steering column covers are self-tapping. To prevent stripping the screws when attaching the ignition switch and steering column covers, the following procedure should be used:

•	Place the screw into position and with slight pressure, rotate the screw in a counter-clockwise (loosening) direction.

•	When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw.

11. Position the new ignition switch to the column and check for proper location of the tab. Install both screws.

Tighten
Tighten both screws to 1.4 N·m (12 lb in).

12. Attach the wiring harness connectors to the ignition switch.
13. Reinstall the upper and lower steering column covers.

Tighten
Tighten the fasteners to 9 N·m (80 lb in).

14. Reinstall the knee bolster trim.

Tighten
Tighten the fasteners to 2 N·m (17 lb in).

15. Reconnect the yellow airbag connector at the base of the steering column and install the CPA.
16. Reinstall the sound insulator panel.

Tighten
Tighten the fasteners to 2 N·m (17 lb in).

17. Reinstall the 15-amp AIR BAG fuse into the fuse box and replace the I/P trim cover.
18. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out.
19. Install the GM Recall Identification Label.

J car - Cavalier/Sunfire with 2.3L or 2.4L Engine (VIN Code D or T)

Important: If the vehicle is a 1995 model with a 2.3L engine and equipped with the original starter solenoid, it will be necessary to enlarge the hole in the large ring terminal on the harness kit prior to installing the harness on the vehicle. Enlarging the terminal hole diameter is required in order for it to fit on the larger diameter battery terminal stud used on the original starter solenoids. If the starter solenoid is not the original, enlarging the hole in the terminal may not be necessary.

Important: 

1. Remove the two 10mm hex head bolts that secure the air cleaner outlet resonator to the throttle body.
2. Disconnect the electrical connector from the sensor in the air cleaner outlet duct.
3. Loosen the clamp that secures the air cleaner outlet duct to the air cleaner housing.
4. Loosen the clamp that secures the air cleaner outlet resonator to the throttle body.
5. Remove the air cleaner outlet duct and the air cleaner outlet resonator from the throttle body.



6. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4).
7. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled.



8. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled.
9. Touch up the drilled hole as necessary using an appropriate anti-corrosion material.
10. On the HARNESS KIT, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
11. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
12. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole.



13. Using the 10mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut.

Tighten
Tighten the bolt to 10 N·m (89 lb in).





Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harnesses together in the next step.

14. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness.
15. Remove the top starter bolt.
16. Raise the vehicle on a suitable hoist.
17. Remove the oil filter.
18. On 1996 models, remove the two bolts that attach the intake manifold brace to the engine block and the two bolts that attach it to the intake manifold. Remove the brace.
19. Remove the bottom starter bolt and remove the starter.
20. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
21. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid.

•	If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 29 and remove the nut. Do NOT perform Steps 22-28 if the stud and nut are in good condition.

•	If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 22 of this procedure. Steps 22-24 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.

22. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal.
23. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
24. Using an appropriate crimping tool, install one end of the butt connector, P/N 12089191, on the short purple wire.
25. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
26. Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
27. Using an appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire.
28. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you have just completed Steps 22-28, proceed to Step 31. Do NOT perform Steps 29-30. If you did NOT perform Steps 22-28, proceed to Step 29.

29. Remove the nut from the starter solenoid "S" terminal and removal all the wires from the terminal.
30. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
31. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit.
32. Using an appropriate crimping tool install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly.
33. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you performed Steps 22-28 earlier, proceed to the next IMPORTANT statement prior to Step 36. Do not perform Steps 34-35. If you did NOT perform Steps 22-28 earlier, proceed to Step 34.

34. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
35. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut.

Tighten
Tighten the nut to 2.5 N·m (22 lb in).

Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.

36. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
37. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
38. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
39. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.

Tighten
Tighten the nut to 11 N·m (8 lb ft).




40. If equipped, remove the 10mm hex head nut from the ground stud on the engine block. If no ground stud is present, remove one of the bolts that attach the starter solenoid to the starter motor. See illustration on page 17 for solenoid bolt location.
41. Install the ground ring terminal (black wire) on the harness kit on the ground stud or solenoid bolt. Install the nut on the stud and tighten to 18 N·m(13 lb ft). If installed on the starter solenoid, install the bolt.

Tighten
Tighten the bolt to 9 N·m (79 lb ft).

42. Install the starter to the engine and install the lower bolt finger tight. Do not tighten at this time.
43. Lower the vehicle.
44. Install the upper starter bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

45. Raise the vehicle.
46. Tighten the lower starter bolt.

Tighten
Tighten the bolt to 90 N·m (66 lb ft).

47. On 1996 models, install the intake manifold brace to the engine block and install the two bolts finger tight. Install the two bolts attaching the brace to the intake manifold.

Tighten

•	Tighten the two bolts attaching the brace to the intake manifold to 24 N·m (18 lb ft).

•	Tighten the two bolts to the engine block to 26 N·m (19 lb ft).

48. Install a new oil filter.
49. Lower the vehicle.
50. Remove the rubber seal from around the top of the throttle body and install it on the bottom of the air cleaner outlet resonator.
51. Position the air cleaner outlet duct and resonator over the throttle body and install the hose to the bottom of the resonator.
52. Install the air cleaner outlet resonator on the throttle body.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

53. Connect the air cleaner outlet duct to the air cleaner housing.

Tighten
Tighten the clamp to 5 N·m (44 lb in).

54. Connect the electrical connector to the sensor in the air cleaner outlet duct.
55. Install the two 10mm hex head bolts that secure the air cleaner outlet resonator.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

56. Reinstall the negative battery cable to the battery.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

57. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.

•	If the starter cranks the engine 6 times in a row, proceed to the next step.

•	If the starter will NOT crank the engine, skip to Procedure A for J car Cavalier/Sunfire.

58. Check the engine oil level and add as necessary.
59. Install the GM Recall Identification Label.

J car - Cavalier/Sunfire with 2.2L Engine (VIN Code 4)

1. Slide the J-nut (1) included in the harness kit on the bottom edge of the upper radiator support (3) so that it is located just to the right of the existing clip (4).
2. With the J-nut in position, use a pencil to mark the location (2) for a 6.35 mm hole (1/4 in) to be drilled.



3. Remove the J-nut and using a 6.35 mm (1/4 in) drill bit, drill a hole in the radiator support at the location marked (2) in the previous step. The above illustration shows the radiator support after the hole has been drilled.
4. Touch up the drilled hole as necessary using an appropriate anti-corrosion material.
5. On the harness kit, strip the insulation back about 6.35 mm (1/4 in) on the purple wire. The purple wire is the only wire on the harness kit that does not have a terminal on it.
6. Using an appropriate crimping tool, install one end of the butt connector included in the harness kit on the purple wire.
7. Slide the J-nut on the bottom edge of the radiator support and over the drilled hole.



8. Using the 10mm hex head bolt provided in the harness kit, attach the relay (1) to the radiator support using the previously drilled hole and J-nut.

Tighten
Tighten the bolt to 10 N·m (89 lb in).





Important: The push-in barbed feature on the plastic harness clips are NOT used when attaching the wiring harnesses together in the next step.

9. Route and attach the service relay harness (3) to the vehicle wiring harness (2) using the two plastic clips (1) already attached to the relay harness.
10. Remove the nut from the "B" terminal of the starter and disconnect all wires and the positive battery cable from the terminal.
11. Visually inspect the condition of the "S" terminal stud and nut on the starter solenoid.

•	If the nut and/or stud appear to be in good condition with little or no sign of corrosion, proceed to Step 19 and remove the nut. Do NOT perform Steps 12-18 if the stud and nut are in good condition.

•	If the nut and/or stud appear to be corroded to the point where the stud may break off if removal of the nut is attempted, proceed to Step 12 of this procedure. Steps 12-14 will require the use of one ADDITIONAL butt connector, P/N 12089191. Obtain the additional butt connector before proceeding.

12. Using wire cutters, cut the purple wire off the "S" terminal of the starter solenoid leaving approximately 50 mm (2 in) of wire on the terminal.
13. Strip the insulation back about 6.35 mm (1/4 in) on the short purple wire that remained on the starter solenoid.
14. Using an appropriate crimping tool, install one end of butt connector, P/N 12089191, on the short purple wire.
15. Using wire cutters, cut the small ring terminal off the end of the red wire on the service harness kit.
16. Strip the insulation back about 6.35 mm (1/4 in) on the red wire.
17. Using the appropriate crimping tool, install the red wire in the other end of the butt connector that is on the starter solenoid short purple wire.
18. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you have just completed Steps 12-18, proceed to Step 21. Do not perform Steps 20-21. If you did NOT perform Steps 12-18, proceed to Step 19.

19. Remove the nut from the starter solenoid "S" terminal and removal all the wires from the terminal.
20. Cut the ring terminal from the vehicle wiring harness purple wire which was removed from the "S" terminal.
21. Strip the insulation back about 6.35 mm (1/4 in) on the purple wires of the vehicle wiring harness and the service harness kit.
22. Using an appropriate crimping tool install the other end of the butt connector, which is already installed on the harness kit, on the purple wire on the vehicle's wiring harness. Crimp the wires together firmly.
23. Using an appropriate tool, heat shrink the yellow tubing on the butt connector to shrink it into position to seal the connection.

Important: If you performed Steps 12-18 earlier, proceed to the next IMPORTANT statement prior to Step 26. Do not perform Steps 24-25. If you did NOT perform Steps 12-18 earlier, proceed to Step 24.

24. Thoroughly clean the interface surfaces of the "S" terminal. Ensure the "S" terminal is snug to the starter solenoid cap.
25. Install the small ring terminal on the red wire of the service harness kit and install it on the "S" terminal. Reinstall the nut.

Tighten
Tighten the nut to 2.5 N·m (22 lb in).

Important: In the next step, make sure the battery cable is the last cable positioned on the starter solenoid "B" terminal so that the nut is tightened against the battery cable.

26. Thoroughly clean the interface surfaces of the "B" terminal on the starter solenoid.
27. Clean the fusible link terminal on the vehicle wiring harness and install it on the starter solenoid "B" terminal.
28. Install the large ring terminal on the harness kit on the starter solenoid "B" terminal.
29. Clean and install the positive battery cable on the starter solenoid "B" terminal. Install the nut.

Tighten
Tighten the nut to 11 N·m (8 lb ft).




30. Remove one of the bolts (2) that attach the starter solenoid (1) to the starter motor.
31. Install the ground ring terminal (black wire) on the harness kit on the bolt and reinstall in the starter.

Tighten
Tighten to 9 N·m (79 lb in).

32. Reinstall the negative battery cable to the battery.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

Important: Do not use a remote starter device in the next step. The vehicle ignition switch must be used to start the vehicle (turn ignition switch to crank position) to verify that the ignition switch is in good working condition.

33. Using the ignition key, start the engine and allow it to run approximately 5 seconds. After 5 seconds, turn the engine off for approximately 5 seconds. Repeat this 6 times.

•	If the starter cranks the engine 6 times in a row, proceed to the next step.

•	If the starter will NOT crank the engine, skip to Procedure A for J car Cavalier/Sunfire.

34. Install the GM Recall Identification Label.

J car Cavalier/Sunfire -- PROCEDURE A (all engines)

1. Remove the small cover from the left side end of the Instrument Panel (I/P) and remove the AIR BAG fuse from the fuse panel.
2. Remove the 7mm hex head screws that attach the right side insulator panel below the I/P and reposition the panel.
3. Remove the Connector Position Assurance (CPA) from the yellow SIR connectors that are clipped to the metal I/P brace near the bottom of the steering column.
4. Disconnect the two yellow connectors.
5. If equipped, remove the tilt column lever.
6. Remove the three screws attaching the lower steering column cover and remove the cover.
7. Remove the upper steering column cover.



8. Remove the two TORX® head screws (2) that attach the ignition switch (3) to the column (1).
9. Remove the ignition switch from the column and disconnect the electrical connectors from the switch. Discard the switch.
10. Connect the electrical connectors to the new ignition switch.

Notice: The ignition switch mounting screws are self-tapping. To prevent stripping the screws when attaching the ignition switch, the following procedure should be used:

•	Place the screw into position and with slight pressure, rotate the screw in a counter-clockwise (loosening) direction.

•	When the original thread is located, the screw will drop slightly; reverse direction and tighten the screw.

11. Position the new ignition switch to the column and install the two attaching TORX® head screws.

Tighten
Tighten to 4 N·m (36 lb in).

12. Install the upper steering column cover.
13. Install the lower steering column cover and attaching screws.

Tighten
Tighten to 4 N·m (36 lb in).

14. If equipped, install a new tilt lever.
15. Connect the two yellow SIR connectors at the base of the steering column.
16. Install the CPA in each connector and clip the connectors to the I/P brace.
17. Position the right side insulator panel to the bottom of the I/P and install the attaching screws.

Tighten
Tighten to 2 N·m (18 lb in).

18. Install the AIR BAG fuse and install the fuse panel cover.
19. Turn the ignition switch to the ON position and verify that the AIR BAG indicator light flashes seven times and goes out.
20. Install the GM Recall Identification Label.

FOR US AND IPC

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

FOR CANADA

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Previous ignition switch replacement and related wiring repair should be considered for possible reimbursement on a case-by-base basis. Dealers should confirm why the ignition switch was replaced and related wiring repaired (i.e., heat damage, fuse blown, etc.) and that there were no other contributing factors (i.e., aftermarket remote starters, alarm systems, etc.). Customers requesting reimbursement for previous ignition switch replacement and related wiring repair must provide proof of ownership at time of repair and the original paid receipt. Such reimbursement should be limited to reasonable and customary charges for this type of service. If deemed appropriate, reimbursement expense should be identified in the "Net Item" column under labor operation V0851. Note that reimbursement for replacement of a steering column tilt lever is allowable since the lever may have been damaged when the ignition switch was replaced. Reimbursement for battery replacement and/or the repair of other starting system components are not covered by this recall.

Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to General Motors.

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

FOR US AND CANADA

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

To coordinate customer requests for this service with the anticipated availability of harness kits, customer notification letters ask 6 cylinder N-car owners to contact their dealers immediately. The owners of 4 cylinder N-cars and J-cars will be asked to contact their dealers in phases during May, June and July.

FOR IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

FOR US AND IPC (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

FOR ALL

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1995-1997 Chevrolet Cavalier and Pontiac Sunfire model cars, and 1996-1997 Buick Skylark, Oldsmobile Achieva, and Pontiac Grand Am model cars. If the engine fails to start and the driver holds the key in the "start" position for an extended period, high current flows through the ignition switch, and sometimes produces enough heat to melt internal switch parts. If the switch is damaged, a fire could occur in the steering column, even with the engine off and the key removed. The fire could spread to the interior of the car which could injure occupants of the car or cause damage to adjoining structures.

The purpose of this letter is to explain this product safety recall, what GM is doing to correct it, and what you can do immediately to reduce the potential for a fire and its consequences. Customers who have experienced this problem usually report that they recently had problems starting their cars. While most of the fires occurred within minutes of an unsuccessful attempt to start the car, others occurred after the car had been unattended for a longer time. If you are experiencing problems starting your car, have it repaired promptly and do not leave the car in a building.

Please know that we understand the concern this may cause and the need to correct is as quickly as we can. Until we are able to install a relay kit in your car that will prevent high current from flowing through the ignition switch, there are two very important precautions you can take to reduce the potential for a fire:

When parts are available, your dealer will (1) install a relay kit that will prevent high current from flowing through the ignition switch and (2) check that your car will start with a properly charged battery and, if necessary, replace the ignition switch. These services will be performed for you at no charge . Battery replacement and other normal maintenance, however, are not covered by this recall.

GM is working with its suppliers as quickly as it can to obtain the relay kits for these cars. Please contact your dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer.

Your dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below:

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

The length of time required to perform this service correction is approximately one (1) hour. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

The attached customer 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 no longer own this vehicle, please let us know by completing the attached and mailing it in the postage paid envelope.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure