Engine - Stalls/No Start/Runs Rough/Code 42 Set

91chevy27

Number: 91-453-6D

Section: 6D

Date: NOV. 1991

Corporate Bulletin No.: 136405

ASE No.: A6, A8


Subject: INTERMITTENT DIAGNOSTIC TROUBLE CODE 42 AND/OR DRIVEABILITY


Model and Year: 1990-91 CAVALIER, CORSICA AND BERETTA WITH 2.2L ENGINE


Condition: Some 1990-91 J and L vehicles equipped with the 2.2L (LM3) engine may intermittently exhibit one or more of the following conditions:

* ECM Diagnostic Trouble Code 42 set, with no trouble found.

* Engine stalling rough running, with no trouble found.

* Intermittent no-start, with no trouble found.

* ECM fuse blown, with no trouble found.

Cause: DIS (Ignition) module lead wiring may be subject to a rub-through condition at the engine wiring harness bracket where it is mounted at the transaxle case. In addition, a similar condition may also exist on the transaxle case near the same location, from a sharp edge formed during case casting, when equipped with manual transaxle.











Correction: Refer to Illustrations for location of repairs.

Repair Procedure:

- Remove secondary ignition wire bracket and wires, set aside.
- Remove clutch cable retainer and cables, set aside. (Manual transaxle only.)
- Un-clip engine wiring harness conduit from retainer, pull back conduit to expose harness.
- Using common "black" electrical tape (locally attained part), begin taping approximately 5 inches back from the point where the main harness breaks out into 3 smaller harnesses.
- While taping to the break-out point, push the individual smaller conduits back and tape up the harnesses as far as possible.

* IMPORTANT: Tape wire harness with 4 layers of tape to insure proper insulation.

* IMPORTANT: If any wires are worn through enough to short out against each other, if strands of wire are broken, or if an "open" wiring condition is found, refer to Section 8A of the applicable Service Manual for proper wiring repair.

- Install wiring harness back into conduit. Before clipping retainer closed, pull the harness towards the center of the vehicle to remove any slack in the harness. This will keep the harness off the transaxle case and away from the transaxle controls.
- Clip harness retainer into position.
- Reinstall clutch cables and retainer. (Manual transaxle only).
- Reinstall secondary ignition cables and bracket.


Warranty and Labor Time Information:

For taping and repositioning harness:

Labor Code: T1789

Labor Time: 0.3 Hours

For wiring repair, taping and repositioning of harness:

Labor Code: T1789

Labor Time 0.4 Hours