CAMPAIGN:A/C EVAPORATOR MAY IGNITE-PLASTIC PLUG REMOVAL

Model and Year: 1984 CHEVROLET G10, G20 and G30 SERIES LIGHT DUTY G-VAN TRUCKS EQUIPPED WITH (RPO C69) FRONT AND REAR A/C SYSTEMS

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 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 which is being sent to owners, the owners are being instructed to contact the nearest Chevrolet Zone Office if their dealer does not remedy the condition within five days of the agreed service date. If the condition is not remedied within a reasonable time, the owners are instructed 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 1984 Chevrolet "G Vans" equipped with a front and rear air conditioning system (RPO C69). Under certain conditions an engine compartment fire could occur if a plastic plug on top of the front air conditioner (A/C) evaporator blower housing was not removed during assembly. This could cause fire damage including burn injuries to passengers remaining in the vehicle.

A vehicle inspection of the A/C evaporator inlet case will be necessary to determine the service procedure and replacement parts required to prevent this from occurring.

VEHICLES INVOLVED

Involved are certain 1984 G10, G20 and G30 Series Light Duty G Van Trucks equipped with (RPO C69) Front and Rear A/C systems. Vehicles involved were built within the following vehicle identification number breakpoints:

Plant From Through ---------- ----- ------- Lordstown E7159985 E7171003 Scarborough E4141940 E4149077

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 the 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 was not shipped any involved vehicles.

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 re- quired modification according to instructions contained in this bulletin.

SERVICE PROCEDURE

Inspect the A/C evaporator inlet case, located on the passenger side of the engine compartment near the hood, for any indication of melting or burning in the area of the rear A/C system blower speed control resistor (see Figure 1).

If there is no damage to the case, follow PROCEDURE A to replace resistor and remove any remaining knockout plug pieces from case.

If there is damage to the case, follow PROCEDURE B (gasoline engine equipped) or PROCEDURE C (diesel engine equipped), depending on the vehicle, to replace the resistor and A/C evaporator inlet case.

PROCEDURE A - GASOLINE OR DIESEL EQUIPPED TRUCKS WITH NO DAMAGE TO A/C EVAPORATOR CASE

1. With ignition key in "off" position, disconnect the negative battery cable.

2. Disconnect the three wire connector from the rear A/C system blower speed control resistor.

3. Remove the two resistor retaining screws from A/C evaporator inlet case.

4. Remove the resistor from the case and discard.

5. Remove any pieces of the rear A/C system blower speed control resistor knockout plug from the opening in the case (see Figure 2). Should a piece of the knockout plug fall into the bottom of the case, it is not necessary to remove it.

6. Install a new resistor, P/N 15591188, in the case. Torque the two resistor retaining screws to 1.2-1.6 Nm (11-14 in. lbs.).

PROCEDURE B - GASOLINE EQUIPPED TRUCKS WITH DAMAGE TO A/C EVAPORATOR INLET CASE

1. With ignition key in "off" position, disconnect the negative battery cable.

2. Remove auxiliary radiator overflow reservoir.

3. Discharge the air conditioning system. Refer to the 1984 Light Duty Truck Service Manual (ST-330-84) for instructions.

CAUTION:

To help avoid personal injury always wear goggles and wrap a clean cloth around fittings, valves and connections when doing work that involves opening the refrigerant system. Always work in a well ventilated area and do not weld or steam clean near any of the air conditioning components.

If refrigerant should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical attention.

4. Disconnect all electrical connections to the A/C evaporator case assembly.

5. Remove right front marker lamp.

6. Remove accumulator inlet and outlet lines and accumulator tank from vehicle.

7. Remove heater hose bracket.

8. Disconnect the plastic water line from the water valve.

9. Remove fasteners securing A/C evaporator case assembly and mounting hardware (three nuts and one screw). Remove case assembly from vehicle.

10. Remove evaporator core retaining screws and separate evaporator and blower inlet case sections.

11. Remove evaporator core, blower motor and case assembly, relay, and resistors from case.

12. Install former front A/C system blower speed control resistor in new case, P/N 3054954, and torque retaining screws to 1.2-1.6 Nm (11-14 in. lbs.). This will provide increased rigidity to prevent cracking the new case when removing knockout plug in Step 13.

13. Carefully punch the A/C system blower speed control resistor knockout plug out of the new case. All pieces of this plug must be removed from the opening. (See Figure No. 2).

14. Install new rear A/C system blower speed control resistor, P/N 15591188, in the new case. Torque the two resistor retaining screws to 1.2-1.6 Nm (11-14 in. lbs.). Discard old resistor.

15. Reinstall the evaporator core, blower motor and cage assembly, and relay on the new case.

16. Assemble A/C evaporator case assembly halves using rope sealant, P/N 3008851 or equivalent, applied to the sealing surfaces of new case.

17. Reinstall the A/C evaporator case assembly on the vehicle following the procedure in reverse. Reseal the case flange to the dash panel using rope sealant, P/N 3008851 or equivalent.

18. Evacuate and recharge the A/C system. Refer to the 1984 Light Duty Truck Service Manual (ST-330-84) for instructions.

PROCEDURE C - DIESEL ENGINE EQUIPPED TRUCKS WITH DAMAGE TO A/C EVAPORATOR INLET CASE

1. Disconnect the negative battery cable.

2. Discharge the air conditioning system. Refer to the 1984 Light Duty Truck Service Manual (ST-330-84) for instructions.

CAUTION:

To help avoid personal injury always wear goggles and wrap a clean cloth around fittings, valves and connections when doing work that involves opening the refrigerant system. Always work in a well ventilated area and do not weld or steam clean near any of the air conditioning components.

If refrigerant should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical attention.

3. Remove auxiliary radiator overflow reservoir.

4. Remove right front marker lamp.

5. Remove blower motor insulation.

6. Disconnect all electrical connections to the A/C evaporator case assembly and remove relay.

7. Disconnect accumulator inlet and outlet lines and move accumulator tank out of the way.

Notice: When removing A/C components, make sure that the component is capped to prevent contamination.

8. Remove the two resistors from the housing.

9. Remove the evaporator core insulation.

10. Remove fasteners securing A/C evaporator case assembly and mounting hardware (three nuts and two screws). Remove case assembly from vehicle.

11. Remove evaporator core retaining screws and separate evaporator and blower inlet case sections.

12. Remove evaporator core, blower motor and cage assembly from housing.

13. Install former front A/C system blower speed control resistor, in new case, P/N 3054954, and torque retaining screws to 1.2-1.6 Nm (11-14 in. lbs.). This will provide increased rigidity to prevent cracking the new case when removing the knockout plug in Step 14.

14. Carefully punch the rear A/C system blower speed control resistor knockout plug out of the new case. All pieces of this plug must be removed from the opening. (See Figure No. 2).

15. Install new rear A/C system blower speed control resistor, P/N 15591188, in the case. Torque the two retaining screws to 1.2-1.6 Nm (11-14 in. lbs.). Discard old resistor.

16. Reinstall the evaporator core, blower motor and cage assembly, and relay on the new case.

17. Assemble A/C evaporator case assembly halves using rope sealant, P/N 3008851 or equivalent, applied to the sealing surfaces of new case.

18. Reinstall the A/C evaporator case assembly on the vehicle following the procedure in reverse. Reseal the case flange to the dash panel using rope sealant, P/N 3008851 or equivalent.

19. Evacuate and recharge the A/C system. Refer to the 1984 Light Duty Truck Service Manual (ST-330-84) for instructions.

Install campaign completion label upon completion of the inspection and/ or modification.

PARTS INFORMATION

Parts that are listed below are to be obtained from the Warehousing and Distribution Division of General Motors (WDDGM). To ensure that these parts will be obtained as soon as possible, they should be ordered from WDDGM on a C.I.O. order with no special instruction code, but order on an advise code (2).

All trucks involved in the campaign will require the following part:

Part Number Quantity Per Vehicle Description ----------- --------------------- ------------ 15591188 1 Resistor

In addition, trucks requiring A/C evaporator inlet case replacement will need the following part:

Part Number Quantity Per Vehicle Description ----------- -------------------- ----------- 3054954 1 Case, Inlet Evaporator

3008851 A/R Rope Sealant

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

Parts Failed Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- ---------- ---- --------- ----- ----- 1 15591188 00 V2310 .2 .1

DESCRIPTION: Inspect A/C evaporator inlet case, remove resistor knock-out plug and install new resistor according to the instructions contained in this bulletin.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- ---------- ---- --------- ----- ----- 2 3054954 13.17 00 V2311 1.9 .1

DESCRIPTION: Inspect and replace A/C evaporator case, resistor and recharge A/C system according to the instructions contained in this bulletin. (Gasoline Engine Only).

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- ---------- ------ ----- 2 3054954 13.17 00 V2312 2.1 .1

DESCRIPTION: Inspect and replace A/C evaporator case, resistor and recharge A/C system according to the instructions contained in this bulletin (Diesel Engine Only).

*Campaign Administrative Allowance

**The $13.17 identified in the "Parts Allowance Column" represents $12.17 for freon and $1.00 seal used in labor operation #V2311 or #V2312.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaiagn 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.

ADMINISTRATIVE PROCEDURE

REFER TO THE CURRENT CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL AND CLAIMS PROCESSING MANUAL FOR CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURES.

Dear Chevrolet Truck Owner:

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

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1984 Chevrolet G Vans equipped with a front and rear air conditioning system (RPO C69). Under certain conditions an engine compartment fire could occur if a plastic plug on top of the front air conditioner (A/C) evaporator/blower housing was not removed during assembly. This could cause fire damage including burn injuries to passengers remaining in the vehicle.

To prevent this from occurring, please contact your Chevrolet dealer on or after the date below to arrange a service date. Your dealer will check the evaporator/blower housing, remove any pieces of the plug, and install a new rear A/C blower speed resistor. If necessary, the dealer will replace the evaporator/blower housing. This service will be completed for you at no charge.

Instructions have been sent to your Chevrolet Truck Dealer. Parts will be available on September 14, 1984. The labor time to inspect the evaporator/ blower housing, remove the knockout plug, and install a new resistor is about 10 minutes. To replace the housing will require about 2 more hours. Please ask your dealer how much additional time will be needed to process your vehicle.

Until you have had this service work completed, do not operate your van with the ignition in the "accessory" position. In addition, do not use the ignition "on" position unless the engine is running. This will eliminate the chance of an engine compartment fire as a result of this condition. Of course, you should contact your Chevrolet Dealer as soon as possible to have the needed service work completed.

Your Chevrolet Truck Dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. How- ever, if you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five days, we recommend you contact the nearest Chevrolet Zone Office, either in person or by telephone. The zone office will assist you and the dealer in getttng your vehicle corrected. The locations and telephone numbers of the zone offices are listed in your Owner's Manual.

After contacting your dealer and the zone office, if you are still not satisfied that we have done our best to remedy this condition without charge within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D. C. 20590, or call 800-424-9393 (Washington, D.C. residents use 426-0123).

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid owner 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 safety and 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.