CAMPAIGN: PULSAIR PIPE HC/CO EMISSIONS REPLACE PULSAIR PIPE

GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1982 CHEVROLET CHEVETTE MODELS EQUIPPED WITH RPO L17 (1.6L L4) ENGINE, AUTOMATIC TRANSMISSION AND FEDERAL EMISSION SYSTEM MAY HAVE CERTAIN DEFICIENCIES IN THE EMISSION CONTROL SYSTEM WHICH MAY RESULT IN INCREASED TAILPIPE HYDRO- CARBON (HC) AND CARBON MONOXIDE (CO) EMISSIONS. THE CAUSE MAY BE ATTRIBUTED TO INTERNAL PULSAIR PIPE CORROSION (AND EVENTUAL PERFORMATION CAUSING AN EXHAUST LEAK), WHICH MAY RESULT IN INCREASED EMISSIONS. THE CARBURETOR FLOW CHARACTERISTICS MAY SHIFT IN THE RICH DIRECTION WITH MILEAGE, FURTHER RESULTING IN INCREASED EMISSIONS. VEHICLES INVOLVED CERTAIN 1982 CHEVROLET CHEVETTE MODELS EQUIPEED WITH RPO L17 (1.6L L4) ENGINE, AUTOMATIC TRANSMISSION AND FEDERAL EMISSION SYSTEM WITHIN THE FOLLOWING VEHICLE PARAMETERS: PLANT FROM THROUGH LAKEWOOD CA100001 CA175260 WILMINGTON CY100001 CY257548 INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. COMPUTER LISTINGS CONTAIN THE COMPLETE VEHICLE IDENTIFICATION 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 REGISTRATION 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. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN WAS NOT SHIPPED ANY INVOLVED VEHICLES. 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 DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO OWNERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNER- SHIP, FROM THIS TIME FORWARD. WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED VEHICLE INVENTORY, OR IT IS IN YOUR DEALERSHIP FOR SERVICE IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING OR RELEASING THE VEHICLE. IN THE INTEREST OF CUSTOMER SATISFACTION, DEALERS SHOULD VERIFY THAT THEY HAVE THE NECESSARY CAMPAIGN PARTS IN STOCK, BEFORE THEY SCHEDULE AND OWNERS VEHICLE FOR THIS SERVICE. IF THERE IS EVIDENCE OF INTENTIONAL DISABLEMENT OF THE EMISSION SYSTEM, OTHER THAN TO RECTIFY PULSAIR LEAKAGE, 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. PARTS INFORMATION PARTS REQUIRED TO COMPLETE THIS MODIFICATION ARE TO BE OBTAINED FROM GENERAL MOTORS WAREHOUSING AND DISTRIBUTION DIVISION (GMWDD) ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ON AN ADVISE CODE (2). PART NUMBER DESCRIPTION QUANTITY 10045075 AIR BLEED HARNESS KIT 1 10045073 SINGLE PORT PULSAIR KIT AS REQUIRED IT IS RECOMMENDED THAT SOME QUANTITY OF AIR BLEED HARNESS KITS AND SINGLE PORT PULSAIR KITS BE ORDERED UPON RECEIPT OF THIS BULLETIN TO ALLOW MODIFICATION OF VEHICLES RETURNED UNEXPECTEDLY SO AS TO MINIMIZE OWNER INCONVENIENCE. CAMPAIGN SERVICE REQUIREMENTS STEP 1 VEHICLES EQUIPPED WITH THE 4 PORT (BLUE) PULSAIR PIPE ASSEMBLY WILL REQUIRE ITS REPLACEMENT WITH THE SINGLE PORT PULSAIR KIT P/N 10045073. FOLLOW INSTRUCTIONS PROVIDED ON P/N 10045074 INSTRUCTION SHEET INCLUDED IN THE KIT. VEHICLES EQUIPPED WITH THE 4 PORT (BLACK) STAINLESS STEEL PULSAIR PIPE ASSEMBLY DO NOT REQUIRE THE SINGLE PORT PULSAIR KIT. STEP 2 IN ADDITION TO STEP 1 ALL VEHICLES MUST HAVE AN AIR BLEED VALVE HARNESS KIT, P/N 10045075. FOLLOW INSTRUCTIONS PROVIDED ON P/N 10045076 INSTRUCTION SHEET INCLUDED IN THE KIT. SERVICE PROCEDURE STEP 1 - SINGLE PORT PULSAIR PIPE INSTALLATION KIT. FOLLOW THE INSTRUCTION SHEET P/N 10045074 INCLUDED IN THE KIT. REPLACE 4 PORT (BLUE) PULSAIR ASSEMBLY WITH A SINGLE TUBE KIT ASSEMBLY (P/N 10045073). (REFER FIGURE 1). THE SINGLE TUBE ASSEMBLY SHOULD BE INSTALLED BY MOUNTING THE SINGLE TUBE FITTING IN THE NUMBER 2 (TWO) CYLINDER EXHAUST PORT. THE TUBE BRACKET SHOULD BE ATTACHED TO THE STUD (PLUG) THAT WILL BE INSTALLED IN THE NUMBER ONE (#1) CYLINDER EXHAUST PORT. PLUGS SHOULD BE INSTALLED IN EXHAUST PORTS #3 AND #4. THE SUPPLIED HOSE CONNECTS THE SINGLE TUBE ASSEMBLY TO THE PULSAIR SOLENOID HOUSING. STEP 2 ALL VEHICLES REQUIRE THE INSTALLATION OF AN AIR BLEED VALVE HARNESS KIT P/N 10045075. FOLLOW THE INSTRUCTION SHEET P/N 10045076 INCLUDED IN THE KIT AIR BLEED VALVE INSTALLATION INSTRUCTIONS 1. REMOVE AIR CLEANER ASSEMBLY. 2. CUT EVAPORATIVE PURGE LINE ABOUT 1/2 INCH OUTBOARD OF FUEL LINE. (SEE VIEW A, FIGURE 3). 3. REMOVE RUBBER ISOLATOR MOUNTED ON TOP OF CARBURETOR. PIERCE 7/32" DIA. HOLE ON REAR FACE OF ISOLATOR, DIRECTLY ABOVE THE "V" SHAPED PROJECTION (SEE VIEW C, FIGURE 3). THE TOP OF THE HOLE SHOULD BE COINCIDENT WITH THE TOP EDGE OF THE RIB ON THE ISOLATOR. REINSTALL THE ISOLATOR ON THE CARBURETOR TORQUING SCREWS TO 2.8 - 4.0 N.M. (25-35 IN. LBS.). 4. CUT THE EGR SIGNAL LINE ABOUT ONE INCH OUTBOARD OF THE HEATER HOSE AT THE REAR OF THE ENGINE (SEE VIEW B, FIGURE 3). 5. ASSEMBLE THE AIR BLEED VALVE AND HARNESS ASSEMBLY TO THE ENGINE. (REFER FIGURE 2). INSERT THE TEE FITTING INTO THE EVAPORATIVE PURGE LINE. PRESS THE 90 DEGREE ELBOW THROUGH THE 7/32 INCH PLASTIC HOLE IN THE CARBURETOR ISOLATOR. INSERT THE "Y" PLASTIC FITTING INTO THE EGR SIGNAL LINE. ASSURE HOSE FROM AIR BLEED VALVE TO ISOLATOR IS DRESSED TIGHT ALONG SIDE OF VACUUM BREAK HOUSING AS SHOWN. 6. REMOVE THE SCREW WHICH ATTACHES THE CHOKE HOUSING TO THE MAIN BODY OF THE CARBURETOR. ATTACH CLIP TO THE CARBURETOR, USING WASHER P/N 11508426; TORQUE SCREW TO 0.6-1.7 N.M. (5-14 IN. LBS.). 7. INSPECT THE INSTALLATION, MAKING SURE THAT THERE ARE NO INTERFERENCE CONDITIONS WITH ADJACENT COMPONENTS. 8. INSTALL AIR CLEANER ASSEMBLY. STEP 3 RESET IGNITION TIMING 1. RESET THE IGNITION TIMING FROM 4 DEGREES BTDC TO 8 DEGREES BTDC AS SPECIFIED ON THE TUNE-UP LABEL PROVIDED. FOLLOW THE INSTRUCTIONS FOR "SET IGNITION TIMING" SECTION 6D OF SERVICE MANUAL. STEP 4 RESET IDLE RPM 1. RESET THE IDLE RPM TO 700 RPM IN DRIVE AND FOLLOW THE INSTRUCTIONS ON THE TUNE-UP LABEL PROVIDED P/N 14100986. STEP 5 RESET CARBURETOR VACUUM BREAK 1. RESET THE CARBURETOR VACUUM BREAK FROM 0.270 INCHES TO 0.300 INCHES. THE ADJUSTMENT SCREW IS SHOWN IN SECTION 6C UNDER "AUTOMATIC CHOKE SYSTEM" AND "VACUUM BREAK ADJUSTMENT." STEP 6 INSTALL TUNE-UP LABEL (INSTRUCTION SHEET P/N 10045076 SHEET 2) - (SEE FIGURE 4). 1. CUT THE OLD LABEL DIAGONALLY ACROSS THE SPECIFICATION PORTION AND REMOVE THE CORNER OF THE LABEL. THE LABEL IS LOCATED ON THE HOOD. 2. REPLACE THE SPECIFICATIONS PORTION OF THE LABEL WITH THE NEW LABEL PROVIDED. 3. ADD THE EMISSION HOSE ROUTING LABEL TO THE AIR CLEANER. STEP 7 1. INSTALL "CAMPAIGN IDENTIFICATION LABEL." CAMPAIGN IDENTIFICATION LABEL EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT CAMPAIGN BULLETIN WILL REQUREI 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 IDENTIFICATION 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. CLAIM INFORMATION 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 INSPECT FOR CAMPAIGN 00 V3230 .2 .1 INVOLVEMENT INSPECT AND INSTALL AIR BLEED HARNESS KIT ONLY 1 10045075 00 V3231 .6 .1 INSPECT AND INSTALL AIR BLEED HARNESS KIT AND SINGLE PORT PULSAIR KIT (IF REQUIRED) 2 10045073 00 V3232 .9 .1 *CAMPAIGN ADMINISTRATIVE ALLOWANCE. **THE PARTS ALLOWANCE SHOULD BE THE SUM TOTAL OF THE CURRENT GMWDD DEALER NET PRICE PLUS 30% OF ALL PARTS REQUIRED FOR THE REPAIR. DEALERS WILL AUTMOATICALLY RECEIVE THE CORRECT LABOR AND MATERIAL ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED. REFER TO THE CHEVROLET CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION. CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION

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.