CAMPAIGN: AIR CONDITIONING REFRIGERANT LEAKAGE

GENERAL MOTORS HAS DETERMINED THAT SOME 1980-1981 SEVILLES AND ELDORADOS MAY HAVE BEEN ASSEMBLED WITH A DEFECTIVE AIR CONDITIONING SYSTEM REFRIGERANT HOSE ASSEMBLY. THE METAL COUPLINGS SECURING HOSE-TO-TUBING ON THE SUBJECT HOSE ASSEMBLY MAY ALLOW REFRIGERANT LEAKAGE AT CERTAIN LOW AMBIENT TEMPERATURES. THIS CONDITION CAN RESULT IN LACK OF PROPER REFRIGERANT CHARGE REQUIRED TO OPERATE THE AIR CONDITIONING SYSTEM OR MAY CAUSE SUFFICIENT REFRIGERANT AND REFRIGERANT OIL DEPLETION TO ALLOW DAMAGE TO THE COMPRESSOR DUE TO INADEQUATE LUBRICATION.

IN ORDER TO PREVENT INCONVENIENCE TO OWNERS WHO MIGHT EXPERIENCE THIS CONDITION, DEALERS WILL BE REQUIRED TO INSTALL AN IMPROVED AIR CONDITIONING SYSTEM REFRIGERANT HOSE ASSEMBLY ON ALL AFFECTED VEHICLES. ADDITIONALLY, A LIMITED NUMBER OF AFFECTED VEHICLES MAY ALSO REQUIRE REPLACEMENT OF BOTH THE AIR CONDITIONING SYSTEM COMPRESSOR AND EXPANSION (ORIFICE) TUBE AS INDICATED IN THE SERVICE PROCEDURE INCLUDED IN THIS BULLETIN.

VEHICLES INVOLVED

ALL 1980 AND 1981 SEVILLES AND ELDORADOS EQUIPPED WITH THE 6.0 LITER V-8 GASOLINE ENGINE (IDENTIFIED AS ENGINE CODE 9 IN THE VEHICLE IDENTIFICATION NUMBER) REQUIRE THIS CAMPAIGN (CADILLAC RECORDS INDICATE THAT A TOTAL OF 112,384 VEHICLES ARE AFFECTED.)

OWNER NOTIFICATION

OWNERS OF ALL AFFECTED VEHICLES WILL BE NOTIFIED BY CADILLAC OF THIS CAMPAIGN. A COPY OF THE OWNER LETTER IS ATTACHED. A LIST OF THOSE VEHICLES INVOLVED, WHICH OUR RECORDS INDICATE WERE SOLD BY YOU, IS ENCLOSED FOR YOUR FOLLOW UP. THIS LISTING CONTAINS 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 FOR THE FOLLOW UP NECESSARY TO COMPLETE THIS CAMPAIGN.

SPECIAL INSTRUCTIONS

OWNERS WHO HAVE INCURRED EXPENSE PRIOR TO ISSUANCE OF THIS CAMPAIGN, FOR AIR CONDITIONING SYSTEM SERVICE THAT MAY RELATE TO THE REFRIGERANT HOSE LEAKAGE PROBLEM, ARE INSTRUCTED IN THE OWNER LETTER TO PROVIDE DEALERS WITH THE ORIGINAL PAID RECEIPTS FOR REVIEW AND CONSIDERATION FOR REIMBURSEMENT. REFER TO THE CREDIT SECTION OF THIS BULLETIN FOR ADDITIONAL DETAILS.

PARTS INFORMATION

PARTS ARE TO BE OBTAINED FROM THE PARTS DISTRIBUTION CENTERS OF THE WAREHOUSING AND DISTRIBUTION DIVISION OF GENERAL MOTORS (GMWDD). THE SPECIFIC PARTS REQUIRED TO CORRECT A VEHICLE WILL DEPEND UPON THE PARTICULAR SERVICE PROCEDURE REQUIRED.

MOST AFFECTED VEHICLES WILL REQUIRE INSTALLATION OF AN IMPROVED REFRIGERANT HOSE ASSEMBLY ONLY. A LIMITED NUMBER OF AFFECTED VEHICLES MAY ALSO REQUIRE REPLACEMENT OF THE COMPRESSOR AND EXPANSION (ORIFICE) TUBE.

THE IMPROVED REFRIGERANT HOSE ASSEMBLY CAN BE IDENTIFIED BY THE P/N 1626210 STAMPED AROUND THE CIRCUMFERENCE OF THE LOW PRESSURE LINE METAL COUPLING AND A YELLOW STRIPE MARKED ON THE MUFFLER AT THE CHARGING PORT AS ILLUSTRATED IN FIGURE 1. (APPROXIMATELY 500 PIECES OF THE INITIAL PRODUCTION RUN OF SERVICE STOCK OF THE IMPROVED HOSE ASSEMBLY WERE PRODUCED WITH NO PART NUMBER IDENTIFICATION; THE 500 SUBJECT PIECES, HOWEVER, CAN BE IDENTIFIED BY THE YELLOW STRIPE).

THE PARTS REQUIRED TO PERFORM EACH PARTICULAR SERVICE PROCEDURE ARE INDICATED BELOW.

1. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY: QTY. REQUIRED PART NO. DESCRIPTION PER VEHICLE 1626210 REFRIGERANT HOSE ASSEMBLY 1 6556521 O-RING; HOSE TO ACCUMULATOR 1 3140600 O-RING; HOSE TO CONDENSOR 1 5887997 O-RING; HOSE TO COMPRESSOR 2 1051053 REFRIGERANT R-12 (30 LB.DRUM) AS REQUIRED* (OR EQUIVALENT) 5416939 REFRIGERANT OIL (1 QT. CONTAINER) AS REQUIRED* (OR EQUIVALENT)

3816659 TIE STRAP 1 (OR EQUIVALENT)

* UP TO A MAXIMUM OF 7 LBS. ** UP TO A MAXIMUM OF 6 OZS.

2. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY AND REPLACEMENT OF COMPRESSOR AND EXPANSION (ORIFICE) TUBE: QTY. REQUIRED PART NUMBER DESCRIPTION PER VEHICLE 1626210 REFRIGERANT HOSE ASSEMBLY 1 6556521 O-RING;HOSE TO ACCUMULATOR 1 3140600 O-RING;HOSE TO CONDENSOR 1 1051053 REFRIGERANT R-12 (30 LB. DRUM) AS REQUIRED* (OR EQUIVALENT)

12300274 COMPRESSOR (INCLUDES TWO O-RINGS 1 P/N 5887997; HOSE TO COMPRESSOR)

3033879 EXPANSION TUBE (INCLUDES ONE 1 O-RING P/N 6555088)

3140600 O RING;LIQUID LINE TO EVAPORATOR 1

3816659 TIE STRAP 1 (OR EQUIVALENT)

9433929 COMPRESSOR BELT (1980 E,K) AS REQUIRED **

9433921 COMPRESSOR BELT (1981, E,K) AS REQUIRED **

* UP TO A MAXIMUM OF 11 LBS. ** NEW COMPRESSOR BELT SHOULD NOT BE INSTALLED UNLESS ORIGINAL BELT IS DAMAGED OR OBVIOUSLY GLAZED AS DESCRIBED IN THE SERVICE PROCEDURE.

IF THERE IS DIFFICULTY IN OBTAINING THESE PARTS USING NORMAL ORDERING PROCEDURES, THE DEALER MAY PLACE A C.I.O. ORDER USING ADVISE CODE "2" WITH NO SPECIAL INSTRUCTION CODE. THE PARTS MAY ALSO BE ORDERED ON A V.I.P. ORDER; HOWEVER, UNLESS PRIOR ZONE APPROVAL IS OBTAINED, THE DEALER WILL BE REQUIRED TO ABSORB ANY SURCHARGE INVOLVED UNDER THE V.I.P. SYSTEM.

IF ANY PROBLEMS ARE ENCOUNTERED IN OBTAINING THESE PARTS, PLEASE FOLLOW THE THREE STEP PROCEDURE AS STATED IN THE GM PARTS EMERGENCY ORDER FOLLOW UP PROCEDURE. (REFER TO GM PARTS POLICY & PROCEDURE MANUAL, EXHIBIT 20, SECTION IV, PAGE 38).

DEALER CAMPAIGN RESPONSIBILITY

DEALERS ARE TO PERFORM THIS RECALL CAMPAIGN, AT NO CHARGE TO THE OWNER, ON ALL AFFECTED VEHICLES, REGARDLESS OF TIME, MILEAGE, OR OWNERSHIP AND ARE TO CORRECT ALL AFFECTED VEHICLES IN DEALER NEW AND USED CAR INVENTORY PRIOR TO THEIR SALE.

WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED CAR INVENTORY IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING THE VEHICLE.

IN ADDITION, DEALERS ARE TO PERFORM THE CAMPAIGN ON ALL AFFECTED VEHICLES AS THEY ARE BROUGHT IN FOR ANY KIND OF SERVICE UNTIL ALL AFFECTED VEHICLES HAVE BEEN CORRECTED.

SERVICE PROCEDURE

BEFORE PROCEEDING WITH THE SERVICE PROCEDURE, THOROUGHLY REVIEW PAGES 1A-14, 1A-33, AND 1A-39 IN THE 1981 CADILLAC SERVICE INFORMATION MANUAL TO FULLY FAMILIARIZE YOURSELF WITH BOTH THE GENERAL PRACTICES TO BE OBSERVED WHEN SERVICING THE AIR CONDITIONING SYSTEM AND, MORE IMPORTANTLY, THE PRECAUTIONS IN HANDLING REFRIGERANT.

1. START ENGINE AND POSITION ELECTRONIC CLIMATE CONTROL TO "AUTO" AND SET TEMPERATURE TO 60 DEG.

2. OPEN HOOD AND FOLLOW THE REQUIRED SERVICE PROCEDURE INDICATED IN THE CHART IN FIGURE 2.

PROCEDURE 1 - REFRIGERANT HOSE ASSEMBLY REPLACEMENT

A. PURGE SYSTEM

CAUTION:

TO REDUCE THE RISK OF PERSONAL INJURY, ALWAYS WEAR EYE PROTEC- TION WHEN DOING WORK THAT INVOLVES OPENING THE REFRIGERATION SYSTEM SINCE REFRIGERANT DISCHARGE MIGHT OCCUR.

1. REMOVE CAPS FROM PRESSURE FITTINGS ON HIGH PRESSURE LINE (MUFFLER) AND LOW PRESSURE SIDE (ACCUMULATOR).

2. INSTALL A LENGTH OF 5/16" DIAMETER CLEAR PLASTIC HOSE OVER THE THREADED END OF GAGE ADAPTER, J-5420. SECURE WITH A CLAMP.

3. PLACE HOSE FROM J5420 INTO A GRADUATED CONTAINER SUCH AS AN EMPTY REFRIGERANT OIL BOTTLE.

4. LOOSELY INNSTALL GAGE ADAPTER, J-5420, ON LOW SIDE PRESSURE FITTING (ACCUMULATOR).

5. TIGHTEN GAGE ADAPTER AND ALLOW SYSTEM TO DISCHARGE AT A RAPID RATE INTO THE CONTAINER. RAPID DISCHARGE MAY CAUSE OIL LOSS; CONTAINER IS NECESSARY TO COLLECT OIL.

6. WHEN THE LOW SIDE OF THE SYSTEM IS COMPLETELY DISCHARGED (NO VAPOR ESCAPING WITH ADAPTER FULLY TIGHTENED DOWN), MEASURE, RECORD, AND DISCARD COLLECTED OIL. THIS SAME QUANTITY OF OIL MUST BE ADDED TO THE SYSTEM BEFORE RECHARGING WITH REFRIGERANT (ADDING OIL IS DESCRIB- ED IN PROCEDURE 1-B, STEP 7).

7. CHECK PRESSURE ON HIGH SIDE FITTING FOR ANY REMAINING PRESSURE. IF PRESSURE IS EVIDENT ON HIGH SIDE, DISCHARGE HIGH SIDE BY SAME PROCEDURE AS FOR LOW SIDE USING ADAPTER J-25498. THIS CONDITION INDICATES A RESTRICTION ON THE HIGH SIDE, POSSIBLY THAT THE EXPANSION (ORIFICE) TUBE IS PLUGGED. CORRECT THIS CONDITION BEFORE REASSEMBL- ING THE SYSTEM.

NOTE: CHECK ACCUMULATOR FOR FROST ON LOWER PORTION. IF EVIDENT, LIQUID REFRIGERANT IS STILL TRAPPED IN THE SYSTEM AND MAY REQUIRE HEAT FOR REMOVAL SUCH AS A WARM, WET CLOTH. DO NOT APPLY ANY FORM OF HEAT IN EXCESS OF 52DEG C (125 DEG F).

8. SYSTEM IS NOW READY FOR SERVICING.

B. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY

1. DISCONNECT NEGATIVE BATTERY CABLE.

2. REMOVE BOLT AND WASHER SECURING HIGH AND LOW PRESSURE HOSE ASSEMBLY TO COMPRESSOR REAR HEAD. REMOVE HOSE ASSEMBLY FROM COMPRESSOR. CAP OPENINGS IN COMPRESSOR.

NOTE: ALL REFRIGERANT SYSTEM CONNECTIONS MUST BE CAPPED OR SEALED IMMEDIATELY TO PREVENT ENTRY OF DIRT AND MOISTURE INTO SYSTEM.

3. CUT TIE STRAP SECURING HIGH PRESSURE HOSE TO RADIATOR OVERFLOW HOSE. DISCONNECT HIGH PRESSURE HOSE FROM CONDENSOR INLET FITTING. CAP OPEN CONDENSOR INLET FITTING.

NOTE: BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING LOOSENING OF ALL O RING AND FLARE TYPE CONNECTIONS.

4. DISCONNECT LOW PRESSURE HOSE FROM ACCUMULATOR FITTING AND REMOVE HOSE ASSEMBLY. CAP OPEN ACCUMULATOR FITTING. 5. REMOVE CAPS FROM COMPRESSOR REAR HEAD. USING TWO NEW O RINGS P/N 5887997 (LUBRICATED WITH REFRIGERANT OIL) AND IMPROVED REFRIGERANT HOSE ASSEMBLY P/N 1626210, POSITION HOSE ASSEMBLY TO COMPRESSOR AND INSTALL BOLT AND WASHER. TIGHTEN TO 46 N.M. (34 FT.LBS.).

NOTE: CARE SHOULD BE TAKEN NOT TO DAMAGE O RINGS DURING INSTALLATION.

6. ROUTE THE HIGH PRESSURE HOSE UNDER THE POSITIVE BATTERY CABLE. REMOVE CAP FROM CONDENSOR INLET, USING A NEW O RING P/N 3140600 (LUBRICATED WITH REFRIGERANT OIL) CONNECT HIGH PRESSURE HOSE TO CONDENSOR FITTING. TIGHTEN TO 24 N.M. (18 FT.LBS.). SECURE THE HIGH PRESSURE HOSE TO THE RADIATOR OVERFLOW HOSE USING TIE STRAP P/N 3816659 OR EQUIVALENT.

NOTE: ALWAYS SLIP THE LUBRICATED O RING ONTO THE FLANGE TUBE TO INSURE PROPER LOCATING AND SEALING.

BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING THE FINAL TIGHTENING OF ALL O RING AND FLARE TYPE CONNECTIONS.

WHEN MAKING CONNECTIONS, USE CARE TO AVOID NICKING O RINGS OR CROSS THREADING CONNECTION THREADS.

7. REMOVE CAP FROM ACCUMULATOR LINE FITTING AND POUR THE EXACT AMOUNT OF FRESH 525 VISCOSITY REFRIGERANT OIL (P/N 5416939 OR EQUIVALENT) LOST DURING RAPID PURGE (AS MEASURED IN PROCEDURE 1-A, STEP 6) DIRECTLY INTO THE ACCUMULATOR. USING A NEW O RING P/N 6556521 (LUBRICATED WITH REFRIGERANT OIL) CONNECT THE LOW PRESSURE HOSE TO THE ACCUMULATOR FITTING. TIGHTEN TO 42 N.M (31 FT.LBS.).

8. CONNECT NEGATIVE BATTERY CABLE.

C. EVACUATING REFRIGERATION SYSTEM

WHENEVER THE AIR CONDITIONING SYSTEM IS OPENED FOR ANY REASON, IT SHOULD NOT BE OPERATED AGAIN UNTIL IT HAS BEEN EVACUATED. FOR THIS OPERATION USE CHARGING STATION, J-23500, TO EVACUATE THE SYSTEM.

1. MAKE CERTAIN THAT ALL VALVES ON CHARGING STATION ARE CLOSED.

2. INSTALL CHARGING STATION LOW PRESSURE LINE TO ACCUMULATOR CHARGING PORT.

3. TURN CHARGING STATION VACUUM PUMP SWITCH ON.

4. OPEN VALVE 1 (LOW PRESSURE CONTROL), AND VALVE 3 (VACUUM CONTROL.)

5. OPERATE TO OBTAIN 27 INCHES OF MERCURY VACUUM, THEN CONTINUE TO OPERATE PUMP FOR FIVE MINUTES. IN ALL EVACUATING PROCEDURES, SPECIFICATIONS OF 27" TO 29" OF MERCURY VACUUM IS USED. THIS EVACUATION CAN ONLY BE ATTAINED AT OR NEAR SEA LEVEL. FOR EACH 1,000 FEET ABOVE SEA LEVEL WHERE THIS OPERATION IS BEING PERFORMED, THIS SPECIFICATION SHOULD BE LOWERED BY ONE INCH OF MERCURY VACUUM. AT 5,000 FEET ELEVATION, ONLY 22" TO 24" OF MERCURY VACUUM CAN NORMALLY BE OBTAINED.

6. WHILE EVACUATING THE SYSTEM, ADD REFRIGERANT TO CYLINDER ON CHARGING STATION BY OPENING VALVES ON REFRIGERANT DRUM AND AT BOTTOM OF CYLINDER (VALVE 4 MUST BE CLOSED). OPEN VALVE ON TOP OF CYLINDER UNTIL APPROXIMATELY 2 1/4 LBS. (1.00 KG.) OF LIQUID IS OBTAINED IN SLIGHT TUBE, AND THEN CLOSE BOTH TOP AND BOTTOM VALVES ON CYLINDER.

7. CLOSE VALVES 1 AND 3 AND TURN OFF VACUUM PUMP SWITCH. SYSTEM SHOULD HOLD VACUUM, UNLESS THERE IS A LEAK.

8. SLOWLY OPEN VALVES 1 AND 4, ALLOWING 1 LB. (.45 KG.) OF REFRIGERANT TO ENTER SYSTEM, THEN CLOSE VALVES.

9. LEAK TEST SYSTEM AS DESCRIBED IN THE 1980 OR 1981 SERVICE INFORMATION MANUAL.

10. CORRECT LEAKS AS REQUIRED. IF A LEAK WAS PRESENT, REPEAT STEPS 4 THROUGH 9.

11. SYSTEM IS NOW READY FOR COMPLETE CHARGE OF REFRIGERANT.

D. ADDING COMPLETE REFRIGERANT CHARGE

1. FILL CYLINDER ON CHARGING STATION WITH REFRIGERANT AS FOLLOWS:

A. OPEN VALVES ON REFRIGERANT DRUM AND BOTTOM OF CYLINDER (VALVE 4 MUST BE CLOSED).

B. OPEN VALVE ON TOP OF CYLINDER UNTIL PROPER LIQUID LEVEL 2 3/4 LBS. (1.25 KG.) IS OBTAINED IN SIGHT TUBE. (NOTE: ONE POUND OF REFRIGERANT WAS PREVIOUSLY ADDED TO THE SYSTEM DURING PROCEDURE 1-C, STEP 8.)

NOTE: THE SYSTEM SHOULD NEVER BE OVERCHARGED BECAUSE EXCESSIVE COMPRESSOR HEAD PRESSURES COULD RESULT.

2. FULLY OPEN VALVES 1 AND 4 TO ALLOW REFRIGERANT TO FLOW INTO SYSTEM.

3. IF 2 1/2 LBS. (1.13 KB.) OF LIQUID REFRIGERANT (3 1/2 LBS. OR 1.59KG. TOTAL) HAS NOT ENTERED INTO SYSTEM, START ENGINE AND RUN AT APPROXIM- ATELY 1500 RPM WITH TRANSMISSION IN PARK POSITION. THIS WILL ALLOW REFRIGERANT REMAINING IN CYLINDER TO BE PULLED INTO SYSTEM. WHEN 1/4 LB. (.11 KG.) REMAINS IN SIGHT TUBE, CLOSE VALVE 4. SHUT OFF ENGINE, CLOSE VALVE 1, DISCONNECT CHARGING STATION LOW PRESSURE LINE AND REINSTALL CAP ON FITTING.

4. START ENGINE. VERIFY PROPE COMPRESSOR OPERATION AND CHECK INTERIOR COOLING PERFORMANCE OF AIR CONDITIONING SYSTEM. SHUT OFF ENGINE.

5. INSTALL CAMPAIGN COMPLETION LABEL DESCRIBED IN THIS BULLETIN.

PROCEDURE 2 - PARTIAL CHARGE

1. FOLLOW STEPS 1 THROUGH 6 OF PROCEDURE 1-C, EVACUATING REFRIGERATION SYSTEM.

2. FULLY OPEN VALVES 1 AND 4 TO ALLOW REFRIGERANT TO FLOW INTO SYSTEM.

3. IF 2 LBS. (.90 KG.) OF LIQUID REFRIGERANT HAS NOT ENTERED INTO SYSTEM, START ENGINE AND RUN AT APPROXIMATELY 1500 RPM WITH TRANSMISSION IN PARK POSITION. THIS WILL ALLOW REFRIGERANT REMAINING IN CYLINDER TO BE PULLED INTO SYSTEM.

NOTE: IF COMPRESSOR IS DAMAGED (I.E., ABNORMALLY NOISY), THE ENGINE SHOULD BE SHUT OFF IMMEDIATELY AND CHARGING STATION DISCONNECTED. REFER TO CHART, FIGURE 2.

WHEN 1/4 LB. (.11 KG.) REMAINS IN SIGHT TUBE, CLOSE VALVE 4. SHUT OFF ENGINE, CLOSE VALVE 1, DISCONNECT CHARGING STATION LOW PRESSURE LINE AND REINSTALL CAP ON FITTING.

PROCEDURE 3 REFRIGERANT HOSE ASSEMBLY, COMPRESSOR, AND EXPANSION TUBE REPLACEMENT

A. PURGE SYSTEM

PURGE SYSTEM AS PREVIOUSLY DESCRIBED IN PROCEDURE 1-A (STEPS 1 THROUGH 8 EXCLUDING STEP 6).

B. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY AND REPLACEMENT OF COMPRESSOR AND EXPANSION TUBE.

1. DISCONNECT NEGATIVE BATTERY CABLE.

2. REMOVE AIR CLEANER.

3. REMOVE BOLT AND WASHER SECURING HIGH AND LOW PRESSURE HOSE ASSEMBLY TO COMPRESSOR REAR HEAD. REMOVE HOSE ASSEMBLY FROM COMPRESSOR.

4. DISCONNECT ELECTRICAL CONNECTORS AT THE LOW PRESSURE SWITCH AND THE COMPRESSOR CLUTCH COIL.

NOTE: IF THE COMPRESSOR HAS SEIZED AND THE CLUTCH COIL HOUSING SHOWS OBVIOUS SIGNS OF EXTREME HEAT BUILD UP, INSPECT THE CLUTCH COIL ELECTRICAL CONNECTOR TO DETERMINE IF THE PLASTIC CONNECTOR HAS MELTED OR SUFFERED OTHER DAMAGE. REPLACE THE CONNECTOR AS REQUIRED (P/N 2973407).

5. LOOSEN POWER STEERING PUMP ADJUSTMENT BOLTS, PIVOT POWER STEERING PUMP TOWARDS CENTERLINE OF ENGINE AND REMOVE DRIVE BELT FROM COMPRESSOR PULLEY

6. REMOVE UPPER BOLT AND NUT SECURING COMPRESSOR REAR UPPER BRACE TO THE INTAKE MANIFOLD AND COMPRESSOR REAR HEAD.

7. REMOVE TWO LOWER COMPRESSOR MOUNTING BOLTS AND REMOVE COMPRESSOR.

8. CUT TIE STRAP SECURING HIGH PRESSURE HOSE TO RADIATOR OVERLOW HOSE. DISCONNECT HIGH PRESSURE HOSE FROM CONDENSOR INLET FITTING. CAP OPEN CONDENSOR INLET FITTING.

NOTE: ALL REFRIGERANT SYSTEM CONNECTIONS MUST BE CAPPED OR SEALED IMMEDIATELY TO PREVENT ENTRY OF DIRT AND MOISTURE INTO SYSTEM.

BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING LOOSENING OF ALL O RING AND FLARE TYPE CONNECTION.

9. DISCONNECT LOW PRESSURE HOSE FROM ACCUMULATOR FITTING AND REMOVE HOSE ASSEMBLY.

10. DISCONNECT THE LIQUID LINE AT THE EVAPORATOR INLET. CAP THE OPEN END OF THE LIQUID LINE SO THAT MOISTURE AND DIRT DOES NOT ENTER SYSTEM.

11. USING NEEDLE NOSE PLIERS, GRIP THE PLASTIC TIP OF THE EXPANSION (ORIFICE) TUBE AND REMOVE THE EXPANSION TUBE AND O RING FROM THE EVAPORATOR INLET LIQUID LINE. CAP EVAPORATOR INLET WHILE SYSTEM IS OPEN TO KEEP AIR, MOISTURE, AND DIRT FROM ENTERING EVAPORATOR. (IN THE EVENT DIFFICULTY IS ENCOUNTERED IN REMOVING THE EXPANSION TUBE, REFER TO SERVICEMAN BULLETIN 81-46, STEPS 3 THROUGH 5 ONLY).

12. COAT THE NEW EXPANSION TUBE O RING. (INCLUDED WITH EXPANSION TUBE) WITH REFRIGERANT OIL AND POSITION ON NEW EXPANSION TUBE P/N 3033879.

13. REMOVE EVAPORATOR INLET CAP AND INSERT THE EXPANSION TUBE INTO THE INLET LINE WITH SHORT END FIRST AND PUSH UNTIL THE TUBE REACHES A FIRM STOP. THIS INDICATES PROPER SEATING OF THE O RING.

14. REMOVE CAP ON CONDENSOR TO EVAPORATOR LIQUID LINE. USING A NEW O RING, P/N 3140600 (LUBRICATED WITH REFRIGERANT OIL), CONNECT THE LIQUID LINE TO THE EVAPORATOR INLET. TIGHTEN TO 17 N.M (12 FT.LBS.)

NOTE: ALWAYS SLIP THE LUBRICATED O RING ONTO THE FLANGE TUBE TO INSURE PROPER LOCATING AND SEALING.

BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING THE FINAL TIGHTENING OF ALL O RING AND FLARE TYPE CONNECTIONS.

WHEN MAKING CONNECTIONS, USE CARE TO AVOID NICKING O RINGS OR CROSS THREADING CONNECTION THREADS.

15. OBTAIN NEW REPLACEMENT COMPRESSOR P/N 12300274. DRAIN ALL REFRIGER- ANT OIL INTO A CLEAN, GRADUATED CONTAINER SUCH AS AN EMPTY REFRIGER- ANT OIL BOTTLE. (THE SERVICE COMPRESSOR COMES FILLED WITH 6 OZ. OF 525 VISCOSITY REFRIGERANT OIL. DUE TO THE OIL REMAINING IN CERTAIN NON REPLACED COMPONENTS, IT IS NECESSARY TO ADD ONLY 4 OZ. OF REFRIGERANT OIL TO THE A/C SYSTEM VIA THE COMPRESSOR FOR THIS PARTICULAR SERVICE PROCEDURE.

16. INSPECT COMPRESSOR DRIVE BELT FOR DAMAGE OR AN OBVIOUS GLAZED CONDI- TION. REPLACE BELT AS REQUIRED USING A NEW BELT (P/N 9433929 1980 E,K OR P/N 9433921 1981 E,K). REFER TO PROCEDURE AS DESCRIBED IN THE 1980 OR 1981 SERVICE INFORMATION MANUAL.

17. POSITION COMPRESSOR AND INSTALL TWO LOWER BOLTS.

18. POSITION COMPRESSOR REAR UPPER BRACE. SECURE WITH ONE BOLT IN THE COMPRESSOR REAR HEAD AND ONE NUT ON THE INTAKE MANIFOLD.

19. TORQUE THE LOWER COMPRESSOR BOLTS TO 40-45 N.M. (29-33 FT.LBS.). TORQUE THE COMPRESSOR REAR UPPER BRACE BOLT TO 75 N.M (55 FT.LBS.) AND THE NUT ON THE INTAKE MANIFOLD TO 40 N.M. (29 FT.LBS.).

20. INSTALL BELT ON COMPRESSOR PULLEY, PIVOT POWER STEERING PUMP AWAY FROM CENTERLINE OF ENGINE TO TENSION THE BELT TO 490 TO 620 NEWTONS (110-140 LBS.) FOR A NEW BELT AND 270 TO 530 NEWTONS (60-120 LBS.) FOR A USED BELT. TIGHTEN POWER STEERING PUMP ADJUSTMENT BOLTS TO 34 N.M (25FT.LBS.)

21. CONNECT THE LOW PRESSURE SWITCH WIRE AND THE COMPRESSOR CLUTCH COIL WIRE TO THE COMPRESSOR.

22. REMOVE PROTECTIVE COVER FROM COMPRESSOR REAR HEAD. USING IMPROVED REFRIGERANT HOSE ASSEMBLY P/N 1626210, POSITION HOSE ASSEMBLY TO COMPRESSOR AND INSTALL BOLT AND WASHER. TIGHTEN TO 46 N.M (34 FT. LBS.)

NOTE: THE SERVICE COMPRESSOR COMES EQUIPPED WITH TWO NEW O RINGS IN THE COMPRESSOR HEAD CAVITY. INSPECT THE O RINGS TO ASSURE THEY ARE CLEAN AND PROPERLY LUBRICATED WITH REFRIGERANT OIL. CARE SHOULD BE TAKEN NOT TO DAMAGE THESE O RINGS DURING HOSE INSTALLATION.

23. ROUTE THE HIGH PRESSURE HOSE UNDER THE POSITIVE BATTERY CABLE. REMOVE CAP FROM CONDENSOR INLET, USING A NEW O RING P/N 3140600 (LUBRICATED WITH REFRIGERANT OIL) CONNECT HIGH PRESSURE HOSE TO CONDENSOR FITTING. TIGHTEN TO 24 N.M (18 FT.LBS.). SECURE THE HIGH PRESSURE HOSE TO THE RADIATOR OVERFLOW HOSE USING THE STRAP P/N 3816659 OR EQUIVALENT.

NOTE: ALWAYS SLIP THE LUBRICATED O RING ONTO THE FLANGE TUBE TO INSURE PROPER LOCATING AND SEALING.

BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING THE FINAL TIGHTENING OF ALL O RING AND FLARE TYPE CONNECTIONS.

WHEN MAKING CONNECTIONS, USE CARE TO AVOID NICKING O RINGS OR CROSS THREADING CONNECTION THREADS.

24. REMOVE CAP FROM ACCUMULATOR LINE FITTING. USING A NEW O RING P/N 6556521 (LUBRICATED WITH REFRIGERANT OIL) CONNECT THE LOW PRESSURE HOSE TO THE ACCUMULATOR FITTING. TIGHTEN TO 42 N.M (31 FT.LBS.).

25. CONNECT NEGATIVE BATTERY CABLE.

C. FLUSH SYSTEM

TO ASSURE REMOVAL OF ANY SYSTEM CONTAMINATION (I.E., METAL PARTICLES) RESULTING FROM A DAMAGED OR SEIZED COMPRESSOR, FOLLOW THE FLUSH PROCEDURE OUTLINED BELOW:

1. ADD A PARTIAL CHARGE OF 2 LBS. (.90 KB.) OF REFRIGERANT TO THE SYSTEM AS PREVIOUSLY DESCRIBED IN PROCEDURE 2 (STEPS 1 THROUGH 3).

2. START ENGINE. ASSURE ELECTRICONIC CLIMATE CONTROL IS SET TO "AUTO" POSITION AND TEMPERATURE IS SET TO 60 DEG. RUN ENGINE AT IDLE FOR A A MINIMUM OF FIVE MINUTES TO ALLOW SUFFICIENT COMPRESSOR OPERATION.

3. SHUT OFF ENGINE AND PURGE SYSTEM AS PREVIOUSLY DESCRIBED IN PROCEDURE 1-A. (STEPS 1 THROUGH 8).

4. DISCONNECT THE LIQUID LINE AT THE EVAPORATOR INLET. CAP THE OPEN END OF THE LIQUID LINE SO THAT MOISTURE AND DIRT DOES NOT ENTER SYSTEM.

5. USING NEEDLE NOSE PLIERS, GRIP THE PLASTIC TIP OF THE EXPANSION (ORIFICE) TUBE AND REMOVE THE EXPANSION TUBE AND O RING FROM THE EVAPORATOR INLET. CAP EVAPORATOR INLET WHILE SYSTEM IS OPEN TO KEEP AIR, MOISTURE, AND DIRT FROM ENTERING EVAPORATOR.

6. USING AN AIR HOSE, BLOW OFF ANY METAL PARTICLES OR OTHER CONTAMI- NANTS FROM EXPANSION TUBE.

7. CLEAN THE EXPANSION TUBE IN SOLVENT. THOROUGHLY DRY THE EXPANSION TUBE AND ASSURE NO METAL PARTICLES OR OTHER CONTAMINANTS ARE PRE- SENT BEFORE REINSTALLATION.

8. REMOVE EVAPORATOR INLET CAP AND POUR THE EXACT AMOUNT OF FRESH 525 VISCOSITY REFRIGERANT OIL (P/N 5416939 OR EQUIVALENT) LOST DURING RAPID PURGE (AS MEASURED IN SYSTEM PURGE, STEP 3 ABOVE) DIRECTLY INTO THE LIQUID LINE.

9. INSERT THE EXPANSION TUBE INTO THE INLET LINE WITH SHORT END FIRST AND PUSH UNTIL THE TUBE REACHES A FIRM STOP. THIS INDICATES PROPER SEATING OF THE O RING.

10. REMOVE CAP ON CONDENSOR TO EVAPORATOR LIQUID LINE. CONNECT THE LIQUID LINE TO THE EVAPORATOR INLET. TIGHTEN TO 17 N.M (12 FT.LBS.)

NOTE: ALWAYS SLIP THE LUBRICATED O RING ONTO THE FLANGE TUBE TO IN- SURE PROPER LOCATING AND SEALING.

BACKING WRENCHES OF THE REQUIRED SIZE MUST BE USED DURING THE FINAL TIGHTENING OF ALL O RING AND FLARE TYPE CONNECTIONS.

WHEN MAKING CONNECTIONS, USE CARE TO AVOID NICKING O RINGS OR CROSS THREADING CONNECTION THREADS.

D. EVACUATING REFRIGERATION SYSTEM

WHENEVER THE AIR CONDITIONING SYSTEM IS OPENED FOR ANY REASON, IT SHOULD NOT BE PUT INTO OPERATION AGAIN UNTIL IT HAS BEEN EVACUATED. EVACUATE SYSTEM AS PREVIOUSLY DESCRIBED IN PROCEDURE 1-C (STEPS 1 THROUGH 11).

E. ADDING COMPLETE REFRIGERANT CHARGE

ADD COMPLETE CHARGE OF REFRIGERANT TO THE SYSTEM AS PREVIOUSLY DESCRIBED IN PROCEDURE 1-D (STEPS 1 THROUGH 4).

INSTALL CAMPAIGN COMPLETION LABEL DESCRIBED IN THIS BULLETIN.

CAMPAIGN COMPLETION LABEL

UPON COMPLETION OF THIS CAMPAIGN, A WHITE CAMPAIGN LABEL (CAT. NO. S-1015) SHOULD BE AFFIXED ON A CLEAN, DRY SURFACE OF THE RADIATOR SUPPORT TIE BAR IN AN AREA CLEARLY VISIBLE WHEN THE VEHICLE'S HOOD IS RAISED. EACH LABEL PROVIDES SPACE TO PRINT IN INK OR TYPE CAMPAIGN NUMBER 81-C-3 AND YOUR FIVE DIGIT DEALER CODE. DEALERS ARE TO TAKE THE STEPS NECESSARY TO INSURE THAT THE NUMBERS ARE PROPERLY RECORDED ON THE LABEL.

CREDIT

CREDIT FOR THIS CAMPAIGN WILL BE ISSUED UPON RECEIPT OF A PROPERLY PREPARED WARRANTY CLAIM AS FOLLOWS:

A. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY ONLY.

PARTS FAILURE LABOR LABOR PART COUNT PART NO. ALLOWANCE CODE OPERATION HOURS

XX 1626210 XX.XX* 96 V1260 .9

*PARTS ALLOWANCE AMOUNT SHOULD REFLECT THE UNIT PRICE(S) OF ONLY THOSE PARTS USED FOR EACH VEHICLE CORRECTION (I.E., O-RINGS AND TIE STRAP PACKAGED IN MULTIPLE QUANTITIES SHOULD BE PRICED BASED UPON ACTUAL QUANTITY REQUIRED PER VEHICLE.)

NOTE: IF THE AIR CONDITIONING SYSTEM REQUIRED A PARTIAL CHARGE TO INSPECT COMPRESSOR OPERATION (REFER TO FIGURE 2 - CHART AND PROCEDURE 2). .5 HR. ADDITIONAL LABOR MAY BE CLAIMED BY LISTING AS "OTHER LABOR HOURS".

B. INSTALLATION OF IMPROVED REFRIGERANT HOSE ASSEMBLY AND REPLACEMENT OF COMPRESSOR AND EXPANSION TUBE.

PARTS FAILURE LABOR LABOR AURHORIZATION PART COUNT PART NO. ALLOWANCE CODE OPERATION HOURS CODE

XX 1626210 XX.XX* 96 V1261 2.4 1A

* PARTS ALLOWANCE AMOUNT SHOULD REFLECT THE UNIT PRICE(S) OF ONLY THOSE PARTS USED FOR EACH VEHICLE CORRECTION (I.E. O-RINGS AND TIE STRAP PACKAGED IN MULTIPLE QUANTITIES SHOULD BE PRICED BASED UPON ACTUAL QUANTITY REQUIRED PER VEHICLE

NOTE: (1) IF THE AIR CONDITIONING SYSTEM REQUIRED A PARTIAL CHARGE TO INSPECT COMPRESSOR OPERATION (REFER TO FIGURE 2 - CHART AND PROCEDURE 2), .5 HR. ADDITIONAL LABOR MAY BE CLAIMED BY LISTING AS "OTHER LABOR HOURS".

(2) IF IT IS DETERMINED THAT A NEW COMPRESSOR BELT IS REQUIRED (REFER TO PROCEDURE 3-B, STEP 16), .5 HR. ADDITIONAL LABOR MAY BE CLAIMED BY LISTING AS "OTHER LABOR HOURS".

(3) IF A NEW COMPRESSOR CLUTCH COIL ELECTRICAL CONNECTOR IS RE- QUIRED (REFER TO PROCEDURE 3-B, STEP 4), .1 HR. ADDITIONAL LABOR MAY BE CLAIMED BY LISTING AS "OTHER LABOR HOURS".

C. OWNER REIMBURSEMENTS FOR PREVIOUSLY INCURRED EXPENSE.

CONSIDERATION SHOULD BE GIVEN TO OWNERS WHO PREVIOUSLY PAID FOR AIR CONDITIOING SYSTEM SERVICE PRIOR TO ISSUANCE OF THIS CAMPAIGN THAT RELATES TO THE REFRIGERANT HOSE LEAKAGE PROBLEM. IN THE EVENT AN OWNER REQUESTS REIMBURSEMENT, THE DEALER SHOULD OBTAIN THE OWNER'S ORIGINAL PAID RECEIPT(S) TO VERIFY THE EXPENSE. OWNERS SHOULD, HOWEVER, BE ADVISED TO RETAIN COPIES OF THESE DOCUMENTS FOR THEIR PERSONAL RECORDS BEFORE SURRENDERING THE ORIGINAL.

THE DEALER IS TO ADVISE THE OWNER THAT THE RECEIPT(S) WILL BE REVIEWED BY A CADILLAC REPRESENTATIVE AND THAT THE OWNER WILL BE ADVISED AS QUICKLY AS POSSIBLE OF THE AMOUNT THAT WILL BE REIMBURSED. WHEN A REQUEST IS APPROVED, THE DEALER IS TO ISSUE THE OWNER A CHECK FOR REIMBURSEMENT.

DEALERS WILL BE CREDITED FOR THIS REIMBURSEMENT THROUGH THE SUBMISSION OF A WARRANTY CLAIM (SUBMITTED AS ONE NET AMOUNT WITH ZONE APPROVAL) AD DETAILED BELOW:

FAILURE LABOR LABOR AUTHORIZATION CODE OPERATION HOURS SUB/MAT/TOW CODE

96 V1262 0 XX.XX 1B

THE LABOR TIME LISTED ABOVE REPRESENTS THE ACTUAL TIME REQUIRED TO PERFORM THE CORRECTION. DEALERS SHOULD APPLY FOR 0.1 ADDITIONAL HOUR FOR ADMINISTRA- TIVE ALLOWANCE AS "OTHER LABOR HOURS".

ALL PARTS MUST BE HELD FOR SCRAPPING IN THE NORMAL MANNER.

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.