PROM - Cold Engine Start/Stall/Surge in Gear: Overview
FILE IN SECTION: 6E - Engine Fuel & EmissionBULLETIN NO.: 57-65-30
DATE: February, 1996
SUBJECT:
Cold Engine Start and Stall, Closed Throttle Idle Surge in Gear (Install A.I.R. Kit, Flash Prom and Three Way Catalytic Converter)
MODELS:
1994-95 Chevrolet Camaro
1994-95 Pontiac Firebird
with 3.4L Pushrod V6 Engine (VIN S - RPO L32) and
Automatic Transmission RPO MD8)
CONDITION
Some owners may comment that their vehicle starts and stalls on the initial cold start of the day. Others may comment on a closed throttle idle surge when the vehicle is in gear. This usually occurs in a parking lot slow driving/idling around a parking lot maneuver. Both conditions typically occur in a 68-89° F ambient temperature range.
CAUSE
Due to variation in individual components and gasolines available it is possible to have a powertrain that, when these things are stacked together, performs temporarily in a lean mode and creates the conditions described above.
CORRECTION
To address this temporary lean running condition during warm up, a new flash calibration has been developed. This new calibration richens the open-loop air/fuel ratio at 20° C to 32° C range (68° F - 89° F). To ensure compliance with Federally mandated emission levels, an A.I.R.. (air injection reaction) kit has been developed along with a new three way catalytic converter. If, after exhausting normal diagnostic procedures, it is determined that the A.I.R. kit along with the calibration is necessary to correct the vehicle, the following procedure should be used to install the A.I.R.. kit. Figures 1 and 2 are a pictorial of the parts installed in the kit.
Remove or Disconnect
1. Battery negative cable
2. Cross car air inlet duct
3. Suitably support vehicle and raise
4. Exhaust pipe bolts at exhaust pipe to three way catalytic converter flange
5. Exhaust crossover pipe nuts
6. Converter hanger bolts
7. Exhaust crossover pipe assembly from studs on exhaust manifolds
8. Lower exhaust system
9. A/C compressor rear bracket bolts to cylinder block
10. Rear two right exhaust manifold bolts
11. Lower vehicle
12. Accessory drive belt
13. Oxygen sensor connector
14. Generator positive cable
15. Electrical connectors from generator
16. Generator rear brace ("S" brace)
17. Generator assembly
18. A/C compressor from front bracket and reposition
19. Generator "Y" brace
20. # 1 spark plug wire
21. EGR electrical connector, EGR adapter and flex pipe
22. Right exhaust manifold front and middle bolts
23. Right exhaust manifold assembly, heat shields and gaskets
Install
1. Transfer oxygen sensor from old manifold and re-install using new oxygen sensor gasket, tighten sensor to 42 N.m (31 lb ft)
2. Exhaust manifold gasket
3. Exhaust manifold assembly and heat shields
Important:
Rear shield must be in place when installing manifold. The rear shield can be held in place by momentarily installing the EGR adapter stud and nut.
4. Right exhaust manifold bolts/screws, tighten to 25 N.m (18 lb ft)
5. Place baffle in right exhaust manifold A.I.R.. pipe hole. Install EGR adapter and flex pipe, tighten adapter stud and bolt to 26 N.m (19 lb ft), tighten flex pipe to inlet manifold bolts to 26 N.m (19 lb ft).
6. Route A.I.R. pipe behind engine and between engine and transmission fill tube, tighten pipe nut
7. A/C compressor to bracket, tighten bolts to 50 N.m (37 lb ft)
8. Generator "Y" brace, tighten bolts at generator to 50 N.m (37 lb ft)
9. Generator rear (S) brace, tighten nut at generator to 50 N.m (37 lb ft), nut at EGR adapter stud to 25 N.m (18 lb ft), tighten long bolt/nut at generator pivot to 50 N.m (37 lb ft).
10. Electrical connectors at generator
11. Positive cable at generator
12. Oxygen sensor electrical connector
13. Accessory drive belt
14. Secondary air injection pipe, secure with 1 bolt, P/N 11515763, at left cylinder head, tighten bolt to 50 N.m (37 lb ft).
15. Check valve to secondary air injection pipe assembly, tighten to 19 N.m (14 lb ft).
16. 90° check valve hose from check valve to secondary air injection check valve pipe bracket with clamps
17. Remove left exhaust manifold top center position bolt and install stud P/N 10191776, tighten to 25 N.m (18 lb ft).
18. Secondary air injection check valve pipe bracket to stud, install nut, 11514518, tighten to 25 N.m (18 lb ft).
19. Cross car air inlet duct
20. Locate electrical connector for air pump typically tucked up near the relay and fuse center on the left front fender well, route the harness to the air pump location next to the stepper motor cruise motor on the left front frame rail
21. Suitably support and raise vehicle
22. Tighten rear manifold bolts to 25 N.m (18 lb ft).
23. Rear A/C compressor brace to engine bolts, tighten to 50 N.m (37 lb ft).
24. Install new three way catalytic converter to exhaust "Y" pipe, tighten clamp to 68 N.m (50 lb ft).
25. Raise cross over pipe with converter into position, install exhaust hanger to converter, tighten bolts to 41 N.m (30 lb ft).
26. Y pipe with seals to exhaust manifold, tighten nuts evenly to 35 N.m (26 lb ft).
27. Tighten converter flange to exhaust pipe bolts to 20 N.m (15 lb ft).
28. Remove 2 bolts from stepper motor cruise bracket, install 2 new studs, P/N 10186163.
29. Install air pump bracket using 2 nuts, P/N 11505005. Use 1 bolt, P/N 10222298.
30. Air pump to bracket, using 3 bolts P/N 11513677, tighten to 12 N.m (9 lb ft).
31. Secondary air injection pump hose and secondary air injection pump air cleaner hose, secure with 2 clamps to air pump.
32. Electrical connector to air pump
33. Lower vehicle
34. Connect air hose from pump to cross car duct, secure with 1 clamp
35. Connect hose from air pump to air pipe at manifold. Secure with 1 clamp.
36. Battery negative cable
37. Install new flash calibration
38. Install new emission label (see chart for correct label application)
39. Start engine and check for leaks