CAMPAIGN: PULSAIR VALVE ASSEMBLY CORROSION
Model and Year: 1983 CHEVROLET CAVALIER EQUIPPED WITH 2.OL ENGINE (RPO LQ5 VIN CODE "P") AND AUTOMATIC TRANSMISSION (FEDERAL EMISSIONS) OR MANUAL AND AUTOMATIC TRANSMISSIONS (CALIFORNIA EMISSIONS)
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 adequately repair within 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 owners 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 which is being sent to owners, the owners are being instructed to contact the nearest Chevrolet Branch Office if their dealer does not remedy the condition within five 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 1983 model year Chevrolet Cavaliers. Internal corrosion of the Pulsair check valve assembly can permit exhaust gas to flow upstream to the plastic shut-off valve possibly melting the valve. It could then be possible for a piece of the melted shut-off valve to be drawn into the air cleaner, and subsequently into the throttle body where it could lodge against the throttle plate. If this condition were to occur, the engine may not return to idle upon release of the accelerator pedal. Although the vehicle can still be stopped with the service brake, loss of accelerator control could result in a vehicle crash without prior warning.
To prevent this condition from occurring, it will be necessary to inspect and, when necessary, replace the following:
A. Pulsair check valve assembly with an assembly incorporating stainless steel components.
B. Shut-off valves with new design valve.
VEHICLES INVOLVED
Involved are certain 1983 model year Chevrolet Cavalier model vehicles equipped with 2.OL engine (RPO LQ5, VIN Code "P") and automatic transmission (Federal Emissions) or manual and automatic transmissions (California Emissions) produced within the following vehicle parameters:
PLANT FROM THROUGH ----- ---- -------
Janesville DJ100001 DJ160436
Lordstown D7100001 D7156251
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 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.
PARTS INFORMATION
Parts required to complete this modification 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. with no special instruction code, but on an advise code (2).
PART NUMBER DESCRIPTION QUANTITY ----------- ----------- -------- 22048208 Pulsair Check Valve 1 as required Assembly
17075121 Shut Off Valve 1 as required
SERVICE PROCEDURE
1. Remove air cleaner and disconnect rubber hoses from Pulsair Check Valve Assembly.
2. Disconnect the following components of the Pulsair Valve System:
a. electrical connector, b. vacuum hoses, c. air outlet pipe from Pulsair Check Valve assembly, and d. air inlet hose to Shut-Off Valve.
3. Remove bolts (2) retaining Pulsair Check Valve Assembly to bracket.
4. Remove the Pulsair Check Valve Assembly and inspect the part number/date code stamped on it (refer to illustration). If the part number is 22048208, Pulsair Check Valve Assembly replacement is not required; proceed to step 5. If the part number is 22035900, replacement may be required after inspecting the date code as follows:
The date code is stamped near the part number (22035900) stamp. This date code consists of 7 digits (i.e., 12983XX) where first three digits are the Julian date code and fourt and fifth digits are year code. If the date code is prior to 12983XX, then replacement of the Pulsair Check Valve Assembly is required. Parts produced on or after date code 12983XX do not require replacement.
5. Inspect the part number on the Shut-Off Valve (refer to illustration). If the number is other than 17075121, replacement is required (see steps 6 & 7); otherwise proceed to step 8.
6. Remove the Shut-Off Valve from the Pulsair Check Valve Assembly.
7. Install the new or inspected Shut-Off Valve into the correct Pulsair Check Valve Assembly.
8. Reassemble the Pulsair Check Valve Assembly by reversing steps 2 & 3.
9. Reconnect rubber hose to Pulsair Check Valve Assembly and reinstall air cleaner.
10. Install Campaign Completion Label.
CAMPAIGN IDENTIFICATION LABEL (Figure 1)
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 five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint 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 LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS ---------------- -- -------- ----- -- ----- --- --- INSPECT ONLY 0 00 V4280 0.6 0.1 NO FURTHER ACTION REQUIRED
INSPECT - REPLACE 1 22048208 ** 00 V4281 0.6 0.1 PULSAIR VALVE ASSY. ONLY
INSPECT - REPLACE 1 17075121 ** 00 V4282 0.6 0.1 SHUT OFF VALVE ONLY
INSPECT - REPLACE 2 22048208 ** 00 V4283 0.6 0.1 PULSAIR VALVE ASSY. & SHUT OFF VALVE
* 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.
Dealers will automatically receive the correct labor and material allowance based an 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.
