CAMPAIGN: REAR BRAKE HOSES

SUBJECT: REAR BRAKE HOSES

MODELS: Certain 1993 Chevrolet Cavalier and Pontiac Sunbird Models (Either Or Both Rear Brake Hose Assemblies)

Certain 1993 Oldsmobile Cutlass Ciera and Buick Century Models (Right Front Brake Hose Assembly)

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1993 Chevrolet Cavalier, Pontiac Sunbird, Oldsmobile Cutlass Ciera and Buick Century models do not comply with Canada Motor Vehicle Safety Standard (CMVSS) 106. The brake hoses on these vehicle were manufactured incorrectly. These vehicles may experience reduced brake effectiveness and/or uneven braking, and a vehicle crash could occur without prior warning.

To prevent these conditions from occurring, dealers are to inspect both rear brake hose assemblies on Chevrolet and Pontiac models and the right front brake hose assembly on Oldsmobile and Buick models and record the date code on each hose assembly. If the date code(s) falls within the specified range, dealers are to replace the brake hose assembly(s).

VEHICLES INVOLVED:

Involved are the following 1993 Chevrolet Cavalier, Pontiac Sunbird, Oldsmobile Cutlass Ciera and Buick Century models:

Model Year Plant From Through ----- ---- ----- ---- ------- J 1993 Lordstown P7263974 P7266012 (Chevrolet) J 1993 Lordstown P7564725 P7565497 (Pontiac) A 1993 Oklahoma City P6405400 P6407607 (Oldsmobile) A 1993 Oklahoma City P6468459 P6468740 (Buick)

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign MUST be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since. the owner may not as yet have received the notification letter.

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

CAMPAIGN PROCEDURE

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 'J' Car 22111811 Hose Asm - Rear Brake 1 or 2

'A' Car 22112744 Hose Asm - Right Front Brake 1

10139097 Gasket - Brake Hose To Caliper Fitting 2

IMPORTANT: Do not order parts unless your dealer listing indicates you have a vehicle involved in this campaign.

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Failed Part Time Allowance ----------- ----------- ----------- -------------- 'A' Car 1A Inspect Only RF Brake Hose N/A .4

'J' CAR 1A Inspect Only Both Rear Brake Hoses N/A .4

'J' CAR 2A Inspect Both Rear Brake Hoses, 22111811 .9 Replace Only One (1) Rear Brake Hose

'J' CAR 3A Inspect Both Rear Brake Hoses, 22111811 1.1 Replace Two (2) Rear Brake Hoses

'A' CAR 4A Inspect and Replace RF Brake Hose 22112744 .8 and Replace Brake Hose to 10139097 Caliper Fitting Gasket

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE: (Illustration for Brake Hose Identification on page 6)

OLDSMOBILE CUTLASS CIERA/BUICK CENTURY

1. Position and raise car on frame type hoist. See service manual section OA.

2. Inspect the right front brake hose assembly and record the date code printed on the hose assembly. See illustration for date code description. If necessary, clean the hose assembly using a rag and soapy water. DO NOT USE A SOLVENT TO CLEAN THE BRAKE HOSE. THIS MAY REMOVE THE DATE CODE. If the date code is located on the upper surface of the hose assembly, it may be necessary to use a mirror to view the code. If a mirror is used, be sure that the code is recorded correctly. Date code is to be recorded on die working copy of the repair order.

3. If the recorded date code matches one of the date codes shown below, continue to step four (4) of this service procedure, and replace the brake hose assembly. If the recorded date code does not match one of the date codes shown below, proceed to step seventeen (17) of this service procedure.

Suspect Date Codes:

X4023 Y4023 Z4023 X4053 Y4053 Z4053 X4063 Y4063 Z4063 X4073 IMPORTANT: --------- CLEAN EACH CONNECTION OF ANY LOOSE SCALE, DIRT, OR OTHER DEBRIS BEFORE DISCONNECTING THE JOINT. IT IS IMPORTANT THAT PROPER CARE BE USED TO AVOID CONTAMINATION OF BRAKE FLUID WITH ANY FOREIGN MATERIAL.

4. Using an 11 mm wrench, disconnect the brake hose fitting (special bolt with hollow shaft and cross hole near head) from the right front brake caliper. Save the brake hose fitting for reinstallation. Remove and dispose brake hose fitting gaskets (washers).

5. Using a 12 mm tube wrench, disconnect the brake pipe nut from the brake hose fitting.

6. Using a screwdriver or other appropriate tool, remove the retaining clip from the brake hose bracket. Save the retaining clip for reinstallation.

7. Using a 13 mm wrench, disconnect the brake hose integral clip from the strut tab. Save the bolt for reinstallation. Remove old brake hose assembly. Destroy old hose assembly to prevent reuse and dispose of destroyed hose.

8. Sub-assemble one (1) brake fitting gasket/washer to the brake hose fitting (special bolt). Place the fitting-gasket sub-assembly through the brake hose block fitting and place the second gasket/washer over the end of the fitting/bolt. Loose assemble the brake hose fitting to the brake caliper.

9. Position brake hose support clip to strut tab and loose assemble using previously removed bolt.

10. Position the end of the brake hose assembly through the brake hose bracket and finger start the brake pipe nut to the brake hose.

11. Make sure that the brake hose is fully seated and properly aligned in the bracket and reinstall the retaining clip to the bracket and hose fitting.

12. Using a 12 mm tube wrench, tighten the brake pipe nut to 15 N.m (11 lbs. ft.).

13. Using an 11 mm wrench, tighten the brake hose fitting to the brake caliper to 44 N.m (32 lbs. ft.).

14. Using a 13 mm wrench, tighten the brake hose integral clip bolt to 25 N.m (18 lbs. ft).

15. Bleed brake system per service manual procedure.

16. Visually check for fluid leaks at all connections.. If any leaks are observed, slightly loosen the involved joint, retighten to specified torque, and rebleed the involved brake.

17. Lower vehicle.

18. Install campaign identification label.

CHEVROLET CAVALIER/PONTIAC SUNBIRD

1. Position and raise car on frame type hoist. See service manual section OA.

2. Inspect the rear brake hose assembly(s) and record the date code(s) printed on the hose assembly. See illustration for date code description. If necessary, clean the hose assembly(s) using a rag and soapy water. DO NOT USE A SOLVENT TO CLEAN THE BRAKE HOSE. THIS MAY REMOVE TBE DATE CODE(S). If the date code is located on the upper surface of the hose assembly(s), it may be necessary to use a mirror to view the code. If a mirror is used, be sure that the code is recorded correctly. Date code is to be recorded on the working copy of the repair order.

3. If the recorded date code(s) matches one of the date codes shown below, continue to step four (4) of this service procedure and replace the brake hose assembly(s). If the recorded date code(s) does not match one of the date codes shown below, proceed to step twelve (12) of this service procedure.

Suspect Date Codes:

X4023 Y4023 Z4023 X4053 Y4053 Z4053 X4063 Y4063 Z4063 X4073

IMPORTANT: --------- CLEAN EACH CONNECTION OF ANY LOOSE SCALE, DIRT, OR OTHER DEBRIS BEFORE DISCONNECTING THE JOINT. IT IS IMPORTANT THAT PROPER CARE BE USED TO AVOID) CONTAMINATION OF BRAKE FLUID WITH ANY FOREIGN MATERIAL.

4. Using a 12 mm tube wrench, disconnect the brake pipe nuts from both ends of the flexible brake hose.

5. Using a screwdriver or other appropriate tool, remove the retaining clips which secure each end of the brake hose to the brake hose brackets. Save the retaining clips for reinstallation. Remove old brake hose assembly. Destroy old hose assembly to prevent reuse and dispose of destroyed hose.

6. Position each end of the new brake hose through the brake hose brackets and finger start the brake pipe nuts to the brake hose.

7. Make sure that the brake hose is fully seated and properly aligned in each brake hose bracket and reinstall the retaining clips to the bracket and hose fitting.

8. Using a 12 mm tube wrench, tighten both brake pipe nuts to 23 N.m (17 lbs. ft).

9. If necessary, replace the opposite side rear brake hose assembly following the procedure in steps four through eight, above.

10. Bleed brake system per service manual procedure.

11. Visually check for fluid leaks at all connections. If any leaks are observed, slightly loosen the involved joint, retighten to specified torque, and rebleed the involved brake.

12. Lower vehicle.

13. Install campaign identification label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label This will indicate that the campaign has been completed.

Dear General Motors Customer.

General Motors of Canada Limited has determined that certain 1993 Chevrolet Cavalier, Pontiac Sunbird, Oldsmobile Cutlass Ciera and Buick Century models do not comply with Canada Motor Vehicle Safety Standard (CMVSS) 106. The brake hoses on these vehicles were manufactured incorrectly. These vehicles may experience reduced brake effectiveness and/or uneven braking, and a vehicle crash could occur without prior warning.

To prevent the possibility of this condition occurring, your dealer will inspect the affected brake hose(s) and, if necessary, replace the brake hose(s).

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

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

Customer Support Department General Motors of Canada Limited

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.