CAMPAIGN: A/C CONDENSER PIPE FATIGUE & INSTALL BRACE
Model and Year: 1989 CHEVROLET CAPRICE WITH 5.0L V8 ENGINE (RPO L03) AND AIR CONDITIONING (RPO C60)
General Motors has determined that certain 1989 Chevro aprice model vehicles equipped with 5.0L V8 engines (RPO L03) and air conditioning (RPO C60) may exhibit fatigue of the air conditioning condenser inlet pipe. This condition occurs as time and mileage accumulate due to loads induced through a relatively short and stiff compressor discharge hose. If this condition continues to exist in the vehicle, the condenser inlet pipe will eventually fracture and discharge its coolant resulting in the loss of vehicle air conditioning.
In order to prevent this condition from occurring, a support brace will be installed to reduce the stress on the inlet pipe, thereby eliminating the need for replacing the hose/pipe assembly and venting Freon to the atmosphere.
VEHICLES INVOLVED
Involved are certain 1989 Chevrolet Caprice model vehicles equipped with 5.0L V8 engines (RPO L03) and air conditioning (RPO C60) built within the following VIN breakpoints:
MODEL YEAR PLANT FROM THROUGH ----- ---- ----- ---- ------- B 1989 Lakewood KA100005 KA154651 B 1989 Arlington KR100010 KR225904
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 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 has no involved vehicles currently assigned.
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 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 in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling 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 correction according to instructions contained in this bulletin.
PARTS INFORMATION
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
Quantity/ Part Number Description Vehicle ----------- ----------- ------- 10164940 Kit, A/C Condenser Tube Support 1 Bracket [Contains (1) 7mm Screw/Bolt, (2) 8mm Screw/Bolt, (1) clip, and (1) bracket]
03037439 Condenser (As Required) 1
03093509 O-Ring (If Condenser 1 Replacement Required)
03094214 O-Ring (If Condenser 1 Replacement Required)
01051053 Refrigerant-12 (30 lbs. can) 3.5 lbs. (If Condenser Replacement Required)
SERVICE PROCEDURE
NOTICE: Replace condenser if necessary referring to condenser replacement procedure, Section 1B, Page 1B-43 of the 1989 "B" Carline Service Manual.
1. Inspect for previously installed, new style, compressor discharge hose/pipe assembly. Illustrations of old and new style compressor discharge hose/pipe assemblies are shown on page 5. If the compressor discharge hose/pipe assembly has been previously replaced with the new style compressor discharge hose/pipe assembly, install Campaign Identification Label and return the vehicle to the owner or dealer stock. If the compressor discharge hose/pipe assembly has not been previously replaced with the new style hose/pipe, proceed with steps 2 through 14 below.
2. Disconnect both battery cables at battery.
3. Remove battery hold-down and remove battery.
4. Remove upper half of fan shroud.
NOTICE: Carefully wedge small section of 2X4 between the top portions of the radiator and A/C condenser for work clearance.
5. Remove the two (2) 8mm screw/bolts that hold the condenser bracket to condenser.
6. Remove two (2) 7mm screw/bolts holding the inlet and outlet tube clamps to the condenser bracket. Leave clamps on tubes and save two (2) 7mm screw/bolts. Remove condenser bracket.
7. Install new condenser bracket (from kit) on condenser using two (2) new 8mm screw/bolts (from kit) and torque to 2.8 - 3.4 NM (24.8 - 30.1 lbs. in.). DO NOT OVERTOROUE.
NOTICE: Figure #1 on page 6 illustrates the installation of the condenser bracket kit. This figure may be helpful in performing steps 6 - 10 of this procedure.
8. Install new clamp (from kit) over upper inlet tube (flat side of clip should face new condenser bracket). Slide clamp forward on tube until hole in clamp lines up with forward hole in condenser bracket and secure clamp with new 7mm screw/bolt (from kit). Torque 2.3 - 2.8 NM (20.4 - 24.8 lbs. in.). DO NOT OVERTORQUE.
NOTICE: Tubes may have to be moved or shifted to get holes in clamps to line up with holes in condenser bracket.
9. Secure existing clamp on upper inlet tube to upper hole at end of condenser bracket with a 7mm screw/bolt (removed previously) and torque to 2.3 - 2.8 NM (20.4 - 24.8 lbs. in.). DO NOT OVERTOROUE.
10. Secure existing clamp on lower outlet tube to lower hole at end of condenser bracket with a 7mm screw/bolt (removed previously) and torque to 2.3 - 2.8 NM (20.4 -24.8 lbs. in.). DO NOT OVERTOROUE.
NOTICE: Make sure lower outlet tube does not contact or rub bottom of new condenser bracket. If tube does contact or rub bracket, bend tube away from condenser bracket.
11. Remove 2x4 and reinstall upper half of fan shroud.
12. Reinstall battery and battery hold down.
13. Reconnect battery cables.
14. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include 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 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 CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT
Inspect - New StyLe Hose/Pipe Assembly -- SK-00 V5720 0.2 0.1 $0.00 Previously Installed
Inspect and Install 1 10164940 ** SK-00 V5721 0.6 0.1 $0.00 Bracket Kit
Inspect - Install Bracket Kit and 4 03037439 ** SK-00 V5722 1.7 0.1 $#.## Replace Condenser
*Campaign Administrative Allowance.
**The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.
***The amount identified in the "Net Amount column should represent the current cost plus 30% for Refrigerant used in conjunction with labor operation V5722.
Dealers will automatically 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.
REIMBURSEMENT
Customer requests for reimbursement of prior repairs to correct a condenser inlet pipe fatigue fracture are to be submitted according to the forms and instructions included in this bulletin (Additional copies to be reproduced locally) within 3 months (90 days) of the date of their owner letter. Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity performing the repair to receive reimbursement. INSTRUCTIONS
1 R.O. # & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice. 2 REQUWST DATE (MONTH, DAY) Date owner or dealer requested reimbursement.
3 VEHICLE IDENTIFICATION NUMBER VIN involved.
4 MILEAGE Enter mileage at time of transaction. (If not available, enter "0".)
5 CC/FC Code is preprinted on form.
6 LABOR OPERATION Labor Operation as referenced in bulletin.
7 SUBLET DMN & Enter total amount of reimbursement. (Do not enter & 8 LINE TOTAL parts or labor hours on claim.)
9 AUTH CODE If the amount of reimbursement approved is $225 or less, no authorization is needed. If the amount exceeds $225, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.
10 REQUESTED Dealer Service Manager enter amounts determined from REIMBURSEMENT owner supplied invoices or paid receipts, which are covered.
11 APPROVED AMOUNT Dealer Service Manager to determine based on reimburse- ment policy of this bulletin.
12 740 STAMP See Item # 11 to determine need for authorization.
13 DEALER REFERENCE INFORMATION A Enter Document Number and Line Number on which claim was submitted.
B Enter Claim Memo Number and Date when claim is credited.
C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.
14 OWNER INFORMATION Must include telephone number.
15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.
16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reinmurse- ment case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.
17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.
This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.
REASON FOR THIS RECALL
General Motors has determined that certain 1989 Chevrolet Caprice model vehicles equipped with 5.0L engines and air conditioning may exhibit fatigue of the air conditioning condenser inlet pipe. This condition occurs as time and mileage accumulate due to loads induced through a relatively short and stiff compressor discharge hose. If this condition continues to exist in the vehicle, the condenser pipe inlet tube will eventually fracture and discharge its coolant resulting in the loss of vehicle air conditioning.
WHAT WE WILL DO
To prevent the possibility of this condition occurring, a support brace will be installed to reduce the stress on the inlet pipe, thereby eliminating the need for replacing the hose/pipe assembly and venting Freon to the atmosphere.
This service will be performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.
If your Caprice has previously experienced a fatigue fracture of the condenser inlet pipe and you paid for all or part of the repair, you may request reimbursement through your Chevrolet dealer within three months (90 days) of this letter. When doing so, you should present the dealer with documentation which reasonably confirms the amount of unreimbursed repair expense due to a fatigue fracture of the condense inlet pipe, the date of the repair, and the person or entity performing the repair.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
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.
