CAMPAIGN: HEATER OUTLET HOSE ASSY. (INSPECT/REROUTE HOSE). Buick Roadmaster 1992

Subject: HEATER OUTLET HOSE ASSEMBLY

Models: 1992 Chevrolet Caprice Sedan and Station Wagon and 1992 Buick Roadmaster Station Wagon

TO: ALL GENERAL MOTORS DEALERS:

General Motors of Canada has determined that certain 1992 Chevrolet Caprice (Sedan and Station Wagon) and Buick Roadmaster (Station Wagon) model vehicles may have been built with the heater outlet hose routed above the heater inlet hose assembly allowing the heater inlet hose to contact the A.I.R. piping. This contact may cause the heater inlet hose to become damaged by either abrasion or heat.

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the assembly if necessary.

VEHICLES INVOLVED:

Involved are the following 1992 Chevrolet Caprice (Sedan and Station Wagon) and Buick Roadmaster (Station Wagon):

1G1BL8379NW114535 1G1BL83E2NW115492 1G1BL8370NW113970 1G1BL83E8NW115478 1G1BL8375NW115570 1G4BR8376NW403020 1G1BL83E6NW114846 1G4BR8370NW402994 1G1BL83E8NW115299 1G4BR8371NW402972 1G1BL83E9NW115604 1G4BR8374NW403016 1G1BL83E0NW114664 1G4BR8378NW403004 1G1BL83E8NW115562 1G4BR8376NW403017 1G1BL83E7NW114516 1G4BR8379NW402993 1G1BL83E5NW114837 1G4BR8372NW403015 1G1BL83EXNW114249 1G4BR8375NW403008 1G1BL83EXNW115501

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:

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, 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, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

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. The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Although most vehicles involved in this campaign will not require any parts to complete this campaign, a very small number of vehicles could experience a severely chafed and/or worn inlet hose. If a vehicle is found which requires a new inlet hose, order the appropriate replacement hose from your General Motors Parts and Illustration Guide.

DUE TO THE SMALL NUMBER OF INLET HOSES REQUIRED (AND To ASSURE AVAILABILITY OF PARTS FOR VEHICLES WHICH EXPERIENCE A SEVERELY CHAFED OR WORN INLET HOSE) DO NOT ORDER AN INLET HOSE UNLESS YOU HAVE INSPECTED AND DETERMINED THAT A VEHICLE HAS A SEVERELY WORN OR CHAFED NUT HOSE.

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 Time Allowance ----------- ----------- -------------- 1A Inspect/No Further Action Required 3 2A Inspect/Reroute Outlet Hose 5 - Inlet Hose Not Chafed

3A Inspect/Reroute Outlet Hose 7 - Inlet Hose Replaced

Time allowance includes 0. 1 hour for dealer administrative detail associated with this campaign. Repair Code 2A and 3A includes $ 1.00 for one half litre of coolant. Parts credit will be based on dealer net plus 30% to cover parts handling.

SERVICE PROCEDURE:

INSPECTION PROCEDURE

Determine if heater inlet hose is routed below heater outlet hose as shown in "INCORRECT" illustration on page 5.

If heater inlet hose is installed under heater outlet hose, "REROUTING PROCEDURE" below must be performed.

If heater inlet hose is routed as shown in "CORRECT" illustration (page 5), no further action is necessary. Install Campaign Identification Label and retum vehicle to customer or to dealer stock.

REROUTING PROCEDURE

1. Park vehicle on a level surface.

2. Remove pressure cap from radiator when engine is cool by:

- Slowly rotating counterclockwise to detent (Do not press down while rotating.)

- Wait until any left over pressure (indicated by a hissing sound) is released.

- After all hissing stops, press down on cap while continuing to rotate counterclockwise.

NOTICE: TO AVOID BEING BURNED, DO NOT REMOVE RADIATOR CAP WHILE ENGINE IS AT NORMAL OPERATING TEMPERATURE. COOLING SYSTEM WILL RELEASE SCALDING FLUID AND STEAM UNDER PRESSURE IF CAP IS REMOVED WHILE ENGINE AND RADIATOR ARE STILL HOT.

3. With a clean drain pan in place, open radiator drain valve.

4. Once enough fluid has drained out of radiator.

- Remove screw from heater outlet hose bracket to cowl panel.

- Remove heater outlet hose from heater core tube (inboard tube) by squeezing both release tabs of quick connect fitting at base of heater core tube and pulling on pipe to disengage fitting (see quick connect fitting illustration on page 5).

5. Inspect inlet hose for signs of severe chafing and/or wear through (not that very few hoses are expected to be chafed or worn). If an inlet hose does require replacement, install new hose following the heater water flow control valve assembly procedures on page 1B-26 of 1992 appropriate Service Manual.

6. Reposition outlet hose properly (under heater inlet hose), align orientation tabs with groves and push hose fitting in place then pull back on hose to ensure proper installation of connector.

NOTICE: Make sure two "O" rings and nylon spacers are in position in quick connect fitting prior to reinstalling outlet hose connection.

Also, make certain quick connect fitting orientation tabs are aligned correctly before connecting quick connect fitting. If quick connect fitting is incorrectly connected, coolant leakage and damage to parts may occur. The quick connect fitting must be pushed on then pulled back to verify proper connector engagement.

Do not rely on an audible click or visual verification to check for a proper connection. If it is necessary to repair quick connect connector use approved service kit which can be obtained from GMSPO.

7. Install outlet hose bracket and screw to cowl panel.

8. Check outboard inlet hose for clearance to A.I.R. pipe. Also, check to assure protective sleeve on heater outlet hose is under heater inlet hose.

9. Close radiator drain valve.

10. Pour drained coolant into radiator until tank is filled.

11. Start engine and run 5 minutes (or until inlet hose is hot).

12. Top off radiator with coolant and install cap.

13. Fill coolant recovery reservoir to hot line with coolant.

NOTICE: "Coolant" is 50/50 mix of water and ethylene glycol.

14. 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:

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the assembly if necessary. This correction will be provided at no charge to you.

Please contact your GM dealer as soon as possible to arrange a service date. 'Mis letter identifies your vehicle. Presentation of this letter to your dealer with assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time. Subsequent to contacting your dealer, further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777 (English), or 1-800-263-7854 (French).

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

Object Number: 76656 Size: FS

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.