Safety Campaign - Generator Rectifier Bridge Short

This bulletin revises and replaces campaign bulletin 99013 dated April, 1999. Campaign bulletin 99013 should be discarded.

The campaign population is expanded to include additional 1999 model year vehicles and some late production 1998 model vehicles. Refer to the Vehicles Involved section.

It is extremely important that dealers make telephone contact with owners of involved vehicles delivered from February 1, 1999 through May 25, 1999. Available data indicates this condition is most likely to occur at low mileage (less than 4,000 miles). Refer to the Customer Notification section.

If dealers know of involved vehicles delivered prior to February 1, 1999 that also have low-mileage, those owners should also be contacted.

The owner letter is revised to include a recommendation that owners not park their vehicles in a garage or other enclosed space due to the potential for an underhood fire, even with the engine off and the KEY REMOVED.

Dealers are advised to disconnect the negative battery cable from the battery terminal on their involved vehicles, AND ANY OTHER INVOLVED VEHICLES ON PREMISES FOR SERVICE. These vehicles should not be parked in a garage or other enclosed space with the battery cables connected.

Due to extremely limited parts availability, all GENERATORS (P/N 10464396) REPLACED UNDER THIS PRODUCT SAFETY CAMPAIGN (and under regular warranty) are to BE RETURNED directly to Delphi Energy & Engine Management Systems via Federal Express Overnight Delivery. Refer to the Parts Return section for shipping information.

GMSPO has placed an order writing control on P/N 10464396. All order for P/N 10464396 will be cancelled until parts availability improves. Initial quantities will be pre-shipped to dealers based on vehicle distribution. Until parts availability improves, all available parts should be utilized to service customer vehicles. DO NOT SERVICE UNSOLD VEHICLES UNTIL FURTHER NOTICE.

The stop delivery message (DCS351) issued on May 25, 1999 will remain in EFFECT until further notice.

The Highway Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-99  Cadillac Sevillemodel vehicles. Some of these vehicles exhibit a condition in which an electrical short may develop in the generator in some of these cars, even when the engine is off and the key is removed. The electrical short could cause an engine compartment fire that could spread to the rest of the vehicle and anything near it.

To prevent the possibility of this condition occurring, dealers are to replace the generator.

Involved are certain 1998 and 1999 Cadillac Seville model vehicles built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer 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.

Important: Due to extremely limited parts availability, generators (P/N 10464396) replaced under this product safety campaign (and under regular warranty) are to be returned directly to Delphi Energy & Engine Management Systems via Federal Express Overnight Delivery to the following address:

Delphi Energy & Engine Management Systems

Plant South Dock

2911 South Scatterfield Road

Anderson, IN 46013

Use account #1776-0110-1 on the Federal Express shipper form for shipping costs.

CAREFULLY package the generator in the replacement part container, along with a copy of the repair order. Please use all packing material when packaging the generator to minimize potential shipping damage. Do not include other unrelated parts with this shipment to Delphi.

This special parts return program will remain in effect until further notice.

GMSPO has placed an order writing control on P/N 10464396. All order for P/N 10464396 will be cancelled until parts availability improves. Initial quantities will be pre-shipped to dealers based on vehicle distribution.

Important: Due to extremely limited initial parts availability, DO NOT USE AVAILABLE PARTS TO SERVICE UNSOLD INVOLVED VEHICLES. Until parts availability improves, all available parts are to be utilized to service customer vehicles.

To help alleviate the parts availability situation, promptly return all replaced generators to Delphi as instructed above.

Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly). It is extremely important that dealers make telephone contact with owners of involved vehicles delivered from February 1, 1999 through May 25, 1999. Available data indicates this condition is most likely to occur at low mileage (less than 4,000 miles). If dealers know of low-mileage involved vehicles delivered prior to February 1, 1999, those owners should also be contacted.

The availability of courtesy transportation to retail customers whose vehicles are involved in this campaign is of the utmost importance in maintaining customer satisfaction. Dealers are to take the steps necessary to ensure that these customers clearly understand that courtesy transportation is available and will be provided upon request at no charge.

Dealers are encouraged to make every effort to demonstrate Cadillac's commitment to our customers' satisfaction during this product safety campaign. Additional labor operations are provided for pick-up and drop-off of customer and loaner vehicles, customer vehicle fuel fill, and customer vehicle interior and exterior clean-up. Refer to the Claims section. THESE SERVICES ARE INTENDED ONLY FOR RETAIL SOLD CUSTOMER VEHICLES, AND ARE NOT TO BE CLAIMED FOR DEMONSTRATOR OR OTHER DEALER-USE VEHICLES.

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

This is especially important for this campaign. Available data indicates this condition is most likely to occur at low mileage (less than 4,000 miles). In summary, whenever a vehicle subject to this campaign enters your 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.

Caution: This procedure requires the vehicle coolant temperature to be below normal operating temperature. For technician safety the coolant temperature should be below 100°F (38°C) before starting the repair.

1. Install the seat and fender covers.
2. Recover the air conditioning system using the published procedures from the 1999 Service Manual.
3. While the air conditioning system is being recovered, perform the following steps:

3.1.	Remove the rear seat cushion and place it on a clean surface with the springs down. Cover the seat cushion to protect if from foreign contamination.

3.2.	Disconnect the negative battery cable from the battery.

3.3.	Disable the Supplemental Restraint System (SRS) using the published procedures from the 1999 Service Manual.

3.4.	Remove the filler panel on top of the radiator support.

4. Remove the radiator cap from the surge tank.
5. Raise and suitably support the vehicle.
6. Drain the engine coolant into a clean container by removing the coolant hose from the generator coolant tube. Save the coolant for reuse. Leave the hose disconnected.
7. Lower the vehicle.
8. Disconnect the electrical connector from the ambient air temperature sensor.
9. Remove the primary hood latch from the support. Disconnect the release cable and set aside.
10. Remove the hood latch support.
11. Remove both headlamps by disconnecting the wiring at the inline connector.
12. Disconnect the air conditioning lines from the condenser. Seal the lines to avoid possible contamination of the air conditioning system. Discard the sealing washers.
13. Remove the radiator retaining bolts and the brackets.
14. Remove the upper coolant hose from the radiator and place it over the top of the engine.
15. Disconnect the driver's side radiator side shield from the radiator support.
16. Remove the transaxle cooler line bracket bolt.
17. Tip the top of the condenser, the radiator, the fan shroud and the cooling fan assembly toward the front of the vehicle.
18. Disconnect the upper transaxle cooler line from the radiator.
19. Remove the lower radiator hose from the radiator.
20. Disconnect the lower transaxle cooler line from the radiator.
21. Open the retainer holding the A/C line to the fan shroud. Position the line out of the retainer.
22. Disconnect the electrical connectors from the coolant fans.
23. Remove the condenser, the radiator, the fan shroud and the cooling fan assembly from the vehicle.
24. Remove the coolant tube and the bracket bolt. Remove the coolant tube and the bracket bolt from the generator.
25. Remove the electrical connections from the generator.
26. Remove the accessory drive belt from the generator pulley.
27. Remove the generator attaching bolts. Remove the generator.
28. Transfer the coolant hose from the old generator to the new generator.

Important: Secure the ground wire when installing the mounting bolts.

29. Install the new generator P/N 10464396 on the vehicle.

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

30. Install the accessory drive belt on the generator pulley. Inspect for the proper belt alignment on all of the pulleys.

Important: When attaching the battery positive (B+) cable to the generator stud, the insulating rubber boot must be completely clear of the stud when the attaching nut is installed and tightened.

Make sure the nut is properly tightened to 13 N·m (10 lb ft) and that no part of the rubber boot is caught under the nut.
Make sure the insulating rubber boot is properly placed over the battery positive cable connection to the generator.
31. Install the electrical connections to the generator.
32. Install the coolant tube and the bracket to the generator.
33. Position the condenser, the radiator, the fan shroud and the cooling fan assembly to the vehicle. Make sure the coolant fan electrical connector and the hood release cable are accessible.
34. Connect the electrical connectors to the coolant fans.
35. Place the A/C line in the retainer on the fan shroud and lock the retainer.
36. Connect the lower transaxle cooler line to the radiator.
37. Connect the lower radiator hose to the radiator.
38. Connect the upper transaxle cooler line to the radiator.
39. Properly position the radiator in the vehicle.
40. Install the transaxle cooler line bracket bolt.
41. Reposition the radiator side shield to the radiator support. Install the retainers.
42. Install and properly position the upper radiator hose to the radiator.
43. Install the radiator retaining brackets and the bolts.
44. Clean and wash hands.
45. Insert 1/4 oz. of R134a tracer dye, P/N 12346303 (or Kent-Moore J 41447), into the top A/C line at the condenser using Kent Moore tool J 41436.
46. Clean the interface on the condenser and the air conditioning lines of any foreign material using a line-free rag.
47. Install the new sealing washers, P/N 52474373, to the air conditioning lines. Install the lines to the condenser assembly.

Tighten
Tighten the nuts to 20 N·m (15 lb ft).

48. Remove any refrigerant residue from the condenser-to-air conditioning line joints by spraying with engine degreaser, P/N 01040436.
49. Connect the wiring for the headlamps. Install the headlamps.
50. Install the hood latch support.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

51. Install the hood release cable into the primary hood latch bracket. Hook up to the hood latch. Install the bolts which retain the hood latch to the bracket.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

52. Connect the electrical connector to the ambient air temperature sensor.
53. Raise and suitably support the vehicle.
54. Install the coolant hose from the radiator to the generator coolant tube.
55. Lower the vehicle.
56. Recharge the air conditioning system. While waiting for the system to recharge, perform the following steps:

56.1.

Connect the negative battery cable to the battery.

56.2.

Properly install the rear seat cushion. Make sure the seat belts are properly positioned.

56.3.

Enable the Supplemental Restraint System (SRS) using the service procedures in the 1999 Service Manual.

57. Start and run the engine with the air conditioning in the maximum position.

Using J 28428-E high intensity black light, inspect for leaks at the air conditioning interfaces which were opened for this repair. Correct as required.

58. Install the filler panel over the top of the radiator.
59. Inspect the transaxle oil for the proper fill. Add transaxle oil, P/N 12346145, as required.
60. Inspect the engine coolant fluid level for the proper fill. Add engine coolant, P/N 12346145, as required.
61. Remove the seat and fender covers.
62. Install the GM Campaign Identification Label.

Each vehicle corrected 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 campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 am to 4:30 pm Eastern Standard Time). Ask for Item Number S-1015 when ordering.

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

Submit a Product Campaign Claim with the information indicated below. Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

DearCadillac Seville Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Cadillac has decided that a defect which relates to motor vehicle safety exists in certain 1998-1999  Cadillac Seville model vehicles. A short may develop in the generator in some of these cars, even when the engine is off and the key is removed. It can cause a fire in the engine compartment that could spread to the rest of the car and to anything near it.Cadillac takes this situation and the overall safety of our customers very seriously. You should return your car to your dealer as soon as possible.

Caution: Until you have had your vehicle serviced for this recall campaign, we strongly recommend that you not park your vehicle in a garage or other enclosed spaces.

The enclosed customer replay card identified your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the postage paid reply card and returning it to us.

Your Cadillac dealer may have already contacted you about this safety campaign. If you have not yet arranged to bring your vehicle in for service, PLEASE CONTACT YOUR CADILLAC DEALER IMMEDIATELY TO DO SO.

Cadillac will replace your vehicle's generator.This service will be performed for you at no charge . While your vehicle is being serviced, we will provide you with alternate transportation.

When your Cadillac dealer has the required parts available, the length of time required to perform this service correction is approximately three hours. Additional time may be required to schedule and process your vehicle. If your dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Generators are not yet available in sufficient quantities to service all affected cars, but every effort is being made to get them to your dealer as soon as possible so that your car can be serviced and returned to you. It may take 2 to 3 weeks or longer for your dealer to obtain the parts required to service your vehicle. While your car is at your dealer awaiting parts, you will be provided alternate transportation.

Your Cadillac dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to service your vehicle within a reasonable time, you should contact the Cadillac Customer Assistance Center at 1-800-458-8006. The deaf, hearing impaired, or speech impaired should call 1-800-833-2622.

If, after contacting the Cadillac Customer Assistance Center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, D.C. 20590 or call 1-800-424-9393 (Washington, D.C. residents use 202-366-0123).

Cadillac places the highest priority on our owner's safety and we sincerely regret any concern this situation may cause you. We want to correct this condition as soon as possible and will do our best to minimize any inconvenience to you.

Sincerely, John F. Smith, General Manager, Cadillac Motor Vehicle Division

General Motors Corporation

Enclosure

Dear Cadillac Seville Customer:

You may have already received notification of this campaign on your vehicle. This notification contains additional information that may be important to your safety and the safety of others.

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Cadillac has decided that a defect which relates to motor vehicle safety exists in certain 1998-1999  Cadillac Seville model vehicles. A short may develop in the generator in some of these cars, even when the engine is off and the key is removed. It can cause a fire in the engine compartment that could spread to the rest of the car and to anything near it.Cadillac takes this situation and the overall safety of our customers very seriously. You should return your car to your dealer as soon as possible.

Caution: Until you have had your vehicle serviced for this recall campaign, we strongly recommend that you not park your vehicle in a garage or other enclosed spaces.

The enclosed customer replay card identified your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the postage paid reply card and returning it to us.

Your Cadillac dealer may have already contacted you about this safety campaign. If you have not yet arranged to bring your vehicle in for service, PLEASE CONTACT YOUR CADILLAC DEALER IMMEDIATELY TO DO SO.

Cadillac will replace your vehicle's generator.This service will be performed for you at no charge . While your vehicle is being serviced, we will provide you with alternate transportation.

When your Cadillac dealer has the required parts available, the length of time required to perform this service correction is approximately three hours. Additional time may be required to schedule and process your vehicle. If your dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Generators are not yet available in sufficient quantities to service all affected cars, but every effort is being made to get them to your dealer as soon as possible so that your car can be serviced and returned to you. It may take 2 to 3 weeks or longer for your dealer to obtain the parts required to service your vehicle. While your car is at your dealer awaiting parts, you will be provided alternate transportation.

Your Cadillac dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. Should your dealer be unable to service your vehicle within a reasonable time, you should contact the Cadillac Customer Assistance Center at 1-800-458-8006. The deaf, hearing impaired, or speech impaired should call 1-800-833-2622.

If, after contacting the Cadillac Customer Assistance Center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, D.C. 20590 or call 1-800-424-9393 (Washington, D.C. residents use 202-366-0123).

Cadillac places the highest priority on our owner's safety and we sincerely regret any concern this situation may cause you. We want to correct this condition as soon as possible and will do our best to minimize any inconvenience to you.

Sincerely, John F. Smith, General Manager, Cadillac Motor Division

General Motors Corporation

Enclosure