CAMPAIGN: JUNCTION BLOCK CORROSION - INSTALL INSULATOR
Subject: PRODUCT SAFETY CAMPAIGN 92C30 - JUNCTION BLOCK CORROSION
Model and Year: 1991-92 CHEVROLET CAPRICE POLICE CARS AND SPECIAL SERVICE WAGONS (IN CORROSION AREAS ONLY)
To: All Chevrolet Dealers
The National Traffic and Motor Vehicle 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 owner 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 owner 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 solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet 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.
DEFECT INVOLVED
General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1991-92 Chevrolet Caprice Police Cars (SEO 9C1) and Special Service Station Wagons (SEO 1A2) located in corrosion areas (Connecticut, Illinois, Indiana, Maine, Massachusetts, Michigan, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont and Wisconsin).
These vehicles may exhibit an electrical "ground out" condition between the 12 volt junction block and the metal inner fender skirt. This condition may cause a melted junction block, smoke, and burned underhood wiring, and may result in a disabled vehicle or a vehicle fire. This condition can occur while the vehicle is in operation, or with the vehicle parked and the ignition in the "OFF" position.
To prevent the possibility of this condition occurring, dealers are to inspect junction blocks for corrosion and install a shielding insulator under the junction block or replace the junction block in severe corrosion cases.
VEHICLES INVOLVED
Involved are certain 1991-92 Chevrolet Caprice Police Cars (SEO 9C1) and Special Service Station Wagons (SEO 1A2) located in corrosion areas and built within the following VIN breakpoints:
YEAR MODEL PLANT CODE FROM THROUGH
1991 B-Car Arlington "R" MR115652 MR152632
1991 B-Car Willow Run "W" MW211611 MW264781
1992 B-Car Arlington "R" NR105982 NR133394
1992 B-Car Willow Run "W" NW108773 NW133167
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
Police fleets/owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of fleet/owner letter included with this bulletin).
DEALER CAMPAIGN RESPONSIBILITY
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 fleets/owners take possession of these vehicles.
Dealers are to service all vehicles subject to this campaign at no charge to fleets/owners, regardless of mileage, age of vehicle, or ownership, from this time forward.
Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.
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.
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
10239854 Junction Block Shielding Insulator 1, If Req'd
10224503 Junction Block 1, If Req'd
10215938 Wheelhouse Panel 1, If Req'd (TO BE REPLACED ONLY WHEN SEVERE CORROSION HAS EXTENDED BEYOND THE JUNCTION BLOCK MOUNTING HOLES)
SERVICE PROCEDURE
1. Disconnect negative battery cable.
2. Remove cables from junction block. Remove junction block from wheelhouse panel.
3. Inspect wheelhouse panel and junction block for corrosion damage. See illustrations on page 4 to determine junction block corrosion category (1, 2, 3 or 4).
4. If junction block has Category 1 or 2 corrosion:
- Clean junction block and wheelhouse panel as needed.
- If needed, coat top of wheelhouse panel with appropriate paint (approximately 2-3 oz. GM P/N 12345321 or equivalent).
- Add insulator, P/N 10239854 (when reinstalling the original junction block in step 5).
If junction block has Category 3 and 4 corrosion:
- Clean wheelhouse panel as needed.
- Thoroughly remove all visible corrosion, then coat top of panel with an appropriate paint as required (approximately 2-3 oz. GM P/N 12345321 or equivalent).
NOTICE:
In the event that perforation/corrosion extends beyond junction block mounting holes (unable to bolt on new junction block), replace wheelhouse panel referring to 1991-92 Chevrolet Caprice Service Manual Section 10-5 for procedure.
- obtain a new junction block for installation in step 5. This new junction block has a heavy material on back, and does not require the insulator.
5. Install junction block (and add insulator if old junction block is being reused - Category 1 or 2). Be certain to use new junction block if inspection revealed category 3 or 4 corrosion.
Torque mounting screws to 2.0 Nm (17 lb. in.) . If mounting screws require replacement, use GM P/N 11509645. If mounting clips require replacement, use GM P/N 10215577.
6. If corrosion perforated wheelhouse panel (and panel did not require replacement in step 4), hoist vehicle, thoroughly clean bottom of panel (tire side), and coat with body undercoating (3M P/N 08883 Rubberized Undercoating or equivalent).
7. Attach cables to posts of junction block, and torque nuts to 34 Nm (24 lb. ft.). If nuts require replacement, use GM P/N 11502812.
8. Reconnect negative battery cable.
9. Install Campaign Identification Label.
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 for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC.
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 PERFORM PC PART NO. ALLOW OP HRS HRS AMT
Inspect & Install Junction Block 1 10239854 ** SK-00 V7850 0.2 0.1 -- Insulator
Inspect & Install Junction Block 1 10239854 ** SK-00 V7851 0.3 0.1 *** Insulator & Paint
Inspect & Install Junction Block & 1 10224503 ** SK-00 V7852 0.3 0.1 *** Paint
Inspect & Install Junction Block & 1 10224503 ** SK-00 V7853 0.6 0.1 *** Paint & Undercoat
Inspect & Install 2 10215938 ** SK-00 V7854 1.3 0.1 @ Junction Block & @ Replace Wheelhouse
* 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 for labor operations V7851, V7852 and V7853 should represent the sum of the current GMSPO Dealer Net price plus 30% for paint, and (when applicable) undercoating to perform this procedure. This column should also include the current GMSPO Dealer Net price plus 30% for clips, nuts or screws required to perform the service procedure.
@ For labor operation V7854, in the event undercoating has been applied to the inner wheelhouse liner, the cost of applying these materials on the new wheelhouse liner should be entered in the Net Amount Column and authorization obtained from the Dealer Assistance Center prior to entering the Campaign Claim. This column should also include the current GMSPO Dealer Net price plus 30% for clips, nuts or screws required to perform the service procedure.
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.
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.
