CAMPAIGN:EGR VALVE INOPERATIVE EGR VALVE MAY PLUG

Model and Year: ALL 1980 CHEVROLET MONZA MODELS EQUIPPED WITH FEDERAL 3.8L 2 BBL (VIN CODE A) ENGINES WITHOUT COMPUTER CONTROLLED EMISSION SYSTEM

TO: ALL CHEVROLET DEALERS

THIS BULLETIN SUPERSEDES 8OC35 DATED MAY, 1984. BECAUSE OF A RECENT COURT RULING, THE PREVIOUS AGE/MILEAGE LIMITATION HAS BEEN DELETED. ALL 1980 MODEL YEAR VEHICLES WITH 3.8L FEDERAL ENGINES ARE TO BE INCLUDED IN THIS CAMPAIGN REGARDLESS OF AGE OR MILEAGE.

General Motors has determined that some 1980 Chevrolet Monza models equipped with Federal 3.8L 2BBL (VIN Code A) engines may be emitting pollutants in excess of Federal Emission Standards.

The EGR valve may have a plugged passage causing the EGR valve not to operate, resulting in an increase of exhaust emissions.

VEHICLES INVOLVED

All 1980 Chevrolet Monza models equipped with Federal 3.8L - 2 BBL (VIN Code A) engines without computer controlled emission systems within the following parameters:

PLANT FROM THROUGH ------ ---- ------- Lordstown 7100001 7305240

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Iden- tification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle regis- tration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of Owner Letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

As a result of a recent court decision clarifying the Federal Emission Recall Program, the previous 5 year/50,000 mile limitation has been deleted from Campaign 8OC35. All vehicles affected by this campaign should be subjected to the technical procedure of this bulletin at no charge to the owner regardless of vehicle age or mileage. If, during this initial inspection, the EGR Valve is found to be inoperative, the valve should be replaced, also at no charge to the owner.

If the valve is functioning satisfactorily, the owner has been requested to have the EGR Valve function checked at 30,000 mile intervals. These 30,000 mile inspections should also be performed at no charge to the owner. However, should any subsequent 30,000 mile inspection indicate EGR valve replacement is necessary, it should be accomplished at no charge to the owner only if the vehicle has less than 50,000 miles.

If there is evidence of intentional disablement of the EGR system, the dealer is to notify the vehicle owner of this condition and ask the owner if he/she wants the system restored. The cost of restoration will be the responsibility of the vehicle owner.

Vehicles in dealer used car inventory are to be campaigned in accordance with the guidelines prescribed in this bulletin, prior to resale of the vehicles.

OWNER REIMBURSEMENT

Owners who have previously paid to have their car repaired because of the vehicle exceeding the original age/mileage limitation have been instructed to present original paid receipts or invoices to receive reimbursement.

PARTS INFORMATION

Dealers are to order EGR Valves from their local GMWDD (EGR Gasket is included with service part):

1980 Federal 3.8L-2 bbl. (VIN Code A) Engine Without Computer Controlled Emission System

EGR VALVE MODEL TRANSMISSION TYPE SERVICE NO. ----- ------------------ ------------ Monza Automatic 17066173 Monza Manual 17066175

DO NOT ORDER AN EGR VALVE FOR THIS THIS CAMPAIGN UNLESS YOU HAVE VEHICLES INVOLVED. THESE VALVES ARE NON-RETURNABLE.

To ensure these parts will be obtained as soon as possible, they should be ordered from GMWDD on a C.I.O. order with no special instruction code, but order on an advise code (2).

TECHNICAL PROCEDURE

A. Inspection of EGR Valve -

1. Raise vehicle hood and cover fenders.

2. With engine at operating temperature, running at idle and with transmission in "Park", place fingers beneath the EGR Valve in order to contact the diaphragm.

CAUTION:

EGR VALVE MAY BE HOT. WEARING GLOVES IS RECOMMENDED TO AVOID BURNING FINGERS.

3. Rapidly increase engine speed to approximately 2,000 rpm and return to idle. Repeat 4 or 5 times with a pause each time. The diaphragm should have moved up and down during this procedure if system is functioning correctly.

4. If no up or down motion was felt when performing the engine rpm increase sequence, as outlined in step 3, check for vacuum at the EGR Valve hose at the higher engine speeds. If vacuum is present, replace EGR Valve, step B.

5. If EGR Valve functions properly, do no replace valve, install campaign identification label. Close hood.

B. EGR Valve Replacement

1. Remove air cleaner assembly.

2. Remove EGR Valve attaching bolts and remove valve. Properly tag valve and hold for disposition by Chevrolet Zone.

3. Remove all traces of gasket material from EGR Valve mounting surface. Do not allow any gasket material to fall into EGR passages.

4. Obtain correct Service EGR Valve (refer to Parts Information above) and install new valve with new gasket. Tighten bolts to 27 N.m. (20 ft. lbs.).

5. Check for proper EGR Valve operation, step A.

6. Install air cleaner and install campaign identification label. Close hood.

DISPOSITION OF PARTS

Replaced parts must be held for disposition by Chevrolet Personnel. Parts must have a claim tag attached showing the repair order and the VIN of the vehicle from which it was removed.

CLAIM INFORMATION

EFFECTIVE WITH THE RECEIPT OF THIS BULLETIN DEALERS ARE REQUESTED NOT TO SUBMIT CAMPAIGN CLAIMS USING LABOR OPERATIONS V2060 AND V2061 AS IDENTIFIED IN CAMPAIGN 8OC35.

Submit a Product Campaign Claim with the information indicated below:

** * Failed Parts Labor Labor Other Repair Performed PC Part No. Allow FC Op Hrs Hrs ---------------- --- -------- ----- --- -- --- ---- Check/Inspect EGR Valve Operation. No Further Action Required. 00 V3250 .2 .1

Check/Inspect EGR Valve Operation and Replace EGR Valve 1 17066173 00 V3251 .3 .1

*Campaign Administrative Allowance.

**The Parts Allowance should be the sum total of the current GMWDD Dealer Net plus 30% of all parts required for the repair.

Dealers will automatically receive the correct labor allowance based on the labor operation performed. Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

REIMBURSEMENT

Claims for customer reimbursement on previously paid repairs are to be submitted to the Zone Office for review and disposition.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint pen.

Each "Campaign Identiffcation Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.

Apply "Campaign Identification Label" only on a clean dry surface.

Dear Chevrolet Owner:

General Motors has determined that your vehicle may be emitting pollutants in excess of Federal Emission Standards. These standards were established to protect the public health or welfare from the dangers of air pollution.

On some 1980 Chevrolet Monza Models equipped with 3.8L 2bbl. V6 engines, the Exhaust Gas Recirculation (EGR) Valve may have a plugged passage. This causes the vehicle not to meet applicable government emission requirements. If not repaired, this non-conformity may cause the vehicle to fail an emission inspection test, if required under state or local law.

As a registered owner of the vehicle identified on the enclosed Owner Reply Card, you may have previously received a letter from Chevrolet concerning the possibility of your vehicle experiencing this EGR Valve plugging condition. That previous letter stated that your vehicle would be inspected free of charge regardless of age or mileage of the vehicle. In addition, any EGR Valve found to be inoperative, would be replaced free of charge if no signs of tampering were found and the vehicle was less than five years old and had less than 50,000 miles of operation.

As a result of a recent court decision clarifying the Federal Emission Recall Program, General Motors is withdrawing the previous 5 year/50,000 limitations on eligibility for recall repair. The recall repair will now be accomplished at General Motors' expense regardless of vehicle age or mileage. The repair includes EGR Valve inspection and EGR Valve replacement if necessary. Subsequent EGR Valve inspections are recommended at 30,000 mile intervals. To encourage your participation, General Motors will pay for these 30,000 mile inspections. However, should any subsequent 30,000 mile inspection indicate EGR Valve replacement is necessary, GM will pay for the EGR Valve replacement only if the vehicle has less than 50,000 miles.

If you have previously encountered the plugged EGR Valve condition and paid for all or part of the repairs, please contact your Chevrolet dealer who will advise you on how to request reimbursement. It will be necessary to present original paid receipts or invoices to verify any expenditures for such repairs so you should have them available when you contact your dealer. You may want to make copies of these documents before providing the originals to your dealer. If your vehicle has not yet been repaired, please contact your Chevrolet Dealer on or after the date shown below to arrange to have the EGR Valve inspected and replaced, if necessary. Should your dealer find that your ECR system has been intentionally disabled at the time this correction is performed, you will be asked if you wish the system to be restored so that it will function as designed. The cost of such restoration will be your responsibility.

Instructions for making this modification have been sent to your dealer. It is estimated that parts will be available at your dealer on April 16, 1986. The labor time necessary to perform this modification is approximately 20 minutes. Please allow additional time for the dealer to process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the inspection to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Owner Identification Reply Card and returning it to us so that we may update our records. Should your dealer not schedule a service date within a reasonable time, you should contact your nearest Chevrolet Zone Office either in person or by telephone for assistance. For your convenience the locations and telephone numbers of the zone offices have been enclosed with this letter.

If your dealer or General Motors are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturers Operation Division (EN-340), United States Environmental Protection Agency, 401 M Street, S.W. Washington, D.C., 20460.

To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle.

After this service is initially performed, you should then have it per- formed as part of your vehicle maintenance at each 30,000 mile interval thereafter. An EGR Maintenance Reminder Card, that should be inserted in your maintenance folder, is enclosed with this letter.

If this inspection is not performed, it is requested that you place this letter in the vehicle glove box for future consideration by a subsequent owner of the vehicle. When this service is performed, the dealer performing the service will install a campaign completion label on the radiator baffle where it is readily visible.

We are sorry to cause you this inconvenience; however, we have taken this action to assure that your vehicle meets applicable government emission requirements and in the interest of your continued satisfaction with our products. We urge your prompt cooperation in this matter.

CHEVROLET ZONE OFFICES

WHEN CALLING FOR ASSISTANCE, PLEASE ASK FOR THE CONSUMER RELATIONS REPRESENTATIVE.

ATLANTA HOUSTON Chevrolet Customer Assistance 13101 N.W. Freeway 30007 Van Dyke Suite 101 Warren, MI 48090 Houston, TX 77040 1-800-222-1020 (713) 460-7301 BIRMINGHAM INDIANAPOLIS 3490 Independence Hwy. 6910 N. Shadeland Ave. Homewood AL 35259 Indianapolis, IN 46220 (205) 287-5306 (317)269-5031 BOSTON JACKSONVILLE Chevrolet Customer Assistance 6622 Southpoint Dr. S. 30007 Van Dyke Suite 200 Warren, MI 48090 Jacksonville, FL 33216 1-800-222-1020 (904) 739-7711 BUFFALO KANSAS CITY 2615 Walden Avenue 10800 Farley Cheektowaga, NY 14225 Suite 100 (716) 891 -7182 Overland Park, KS 6621 o CHARLESTON (913) 451-4380 Chevrolet Customer Assistance LOS ANGELES 30007 Van Dyke 233 Wilshire Blvd. Warren, MI 48090 Suite 800 1-800-222-1020 Santa Monica, CA 90401 CHARLOTTE (213) 393-9356 Chevrolet Customer Assistance LOUISVILLE 30007 Van Dyke 9100 Shelbyville Rd. Warren, MI 48090 Paragon Place, Suite 200 1-800-222-1020 Louisville, KY 40222 CHICAGO (502) 423-5858 475 Alexis R. Shuman Blvd. MEMPHIS Naperville, IL 60566 866 Ridgeway Loop Ave. (312) 961 -6380 Memphis, TN 38117 CINCINNATI (901) 756-3360 Chevrolet Customer Assistance MILWAUKEE 30007 Van Dyke 333 Bishops Way Warren, MI 48090 Brookfield, WI 53005 1-800-222-1020 (414)784-2578 CLEVELAND MINNEAPOLIS 25000 Great Northern Corporate Center 7600 Metro Blvd. Suite 444 Edina, MN 55435 North Almsted, OH 44070 (612) 830-4044 (216) 265-5600 NEW ORLEANS DALLAS 35451-10 Service Road 130 E. Carpenter Freeway Metairie, LA 70002 Irving, TX 75062 (504) 888-9013 (214) 659-5441 NORTH JERSEY DENVER 9 Sylvan Way 5460 S. Quebec St. Parsippany, NJ 07054 Suite 330 (201) 993-4155 Englewood, CO 80111 OAKLAND* (303) 930-5720 39465 Paseo Padre Parkway DETROIT Fremont, CA 94538 Chevrolet Customer Assistance (415) 498-5080 30007 Van Dyke OKLAHOMA CITY Warren, MI 48090 6307 Waterford Blvd. 1-800-222-1020 Suite 200 FARGO Oklahoma City, OK 73118 1111 38th St. So. (405) 841-5000 Fargo, ND 58103 OMAHA (701) 282-4451 10836 Old Mill Rd. Omaha, NE 68154 (402) 399-5515

PEORIA 3425 N. Dries Lane Peoria, IL 61604 (309) 688-1021 PHILADELPHIA 851 Duportail Rd. Wayne, PA 19087 (215) 296-6600 PHOENIX 1625 W. Fountainhead Pky. Tempe, AZ 85282 (602) 829-6201 PITTSBURGH 2 Penn Center W. Suite 200 Pittsburgh, PA 15276 (412) 928-5125 PORTLAND* 10300 S.W. Greenburg Road, Suite 500 Portland, OR 97223 (503) 293-5000 RICHMOND Chevrolet Customer Assistance 30007 Van Dylle Warren, MI 48090 1-800-222-1020 SALT LAKE CITY 303 East South Temple Salt Lake City, UT 84111 (801) 534-7125 ST. LOUIS 83 Progress Parkway Maryland Heights, MO 63043 (314) 895-8608/8609 SYRACUSE Chevrolet Customer Assistance 30007 Van Dyke Warren, MI 48090 1-800-222-1020 TARRYTOWN 2500 Westchester Ave. Purchase, NY 10577 (914) 251 -5121 WASHINGTON 1395 Piccard Drive Rockville, MD 20850 (301) 258-1444 CENTRAL OFFICES UNITED STATES Chevrolet Motor Division Consumer Relations Dept. Chevrolet Central Office Warren, Michigan 48090 (313) 492-5500 CANADA Customer Services Department General Motors of Canada Limited Oshawa, Ontario LlJ 5Z6 (416) 644-6624

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.