PI0296

File in Section:
Service Bulletin
Bulletin No.:
Date:
PI0296
November, 2010
PRELIMINARY INFORMATION
Subject:
Malfunction Indicator Lamp (MIL) Illuminated, DTC P0201, P0300 and/or P0301 Set,
Engine Misfire (Inspect Wiring Harness Insulation of Fuel Injector #1 for Chafing,
Repair as Outlined)
Models:
2008‐2011 Chevrolet Cobalt, HHR, Malibu
2008‐2010 Pontiac G5, G6
Equipped with 2.4L Engine RPO LE5 or LE9
The following information may be helpful if the vehicle exhibits the symptoms described in this PI.
Condition/Concern
Some customers may comment that the malfunction indicator lamp (MIL) is illuminated and the engine has a misfire.
The technician may observe on a scan tool DTC P0201, P0300 and/or DTC P0301 set as Current or in History.
This condition may be caused by chafing of the wiring harness insulation for fuel injector #1.
Recommendation/Instructions
Important: DO NOT replace the ECM or the fuel injector for the above condition.
1. Perform the Diagnostic System Check ‐ Vehicle.
⇒ If DTC P0201, P0300 and/or P0301 are set as Current or in History, proceed to Step 2.
⇒ If DTC P0201, P0300 and/or P0301 are not set as Current or in History, refer to > Symptoms ‐ Vehicle >
Symptoms ‐ Engine Controls in SI.
2. Turn OFF the ignition.
3. Inspect the wiring harness insulation of fuel injector #1 for chafing in the area of the alternator and the upper
radiator cooling hose at the engine.
⇒ If the wiring harness insulation of fuel injector #1 has chafing, then repair as needed. Refer to Power and
Signal Distribution > Wiring Systems and Power Management > Diagnostic Information and Procedures >
Repairing Damaged Wire Insulation in SI.
⇒ If the wiring harness insulation of fuel injector #1 does not have chafing, then refer to Diagnostic Trouble
Code (DTC) List ‐ Vehicle in SI.
2541228
4. Cut a piece of plastic convoluted tube (2), approximately 38 mm (1.5 in) in length to install on the wiring harness
(1) of fuel injector #1.
2541230
5. Wrap and secure the wiring harness of fuel injector #1 in the plastic convoluted tube.
6. Turn ON the ignition. Clear all DTCs with a scan tool.
7. Start the engine and observe the following control circuit status parameters for fuel injector #1:
• Injector Ckt Short Gnd Test Status
• Injector Ckt Open Test Status
• Injector Ckt Short Volts Test Status
Each parameter should display OK or Not Run.
8. With the engine running, observe the DTC information with a scan tool. DTC P0201 should not set.
Warranty Information
For vehicles repaired under warranty, use:
Labor
Operation
N6653
Description
Wire to Wire Repair
Labor
Time
Use
Published
Labor
Operation
Time