CAMPAIGN: PCV SYSTEM CHANGE

REVISION: CAMPAIGNS 97061(A)

APRIL, 1998

THIS BULLETIN CANCELS AND REPLACES BULLETIN 97061, ISSUED NOVEMBER, 1997 THE SERVICE PROCEDURE, PARTS INFORMATION, AND CLAIM INFORMATION HAS BEEN REVISED TO INCLUDE 1995 STRIPPED CHASSIS'

ALL COPIES OF BULLETIN 97061 SHOULD BE DESTROYED ______________________________________________________________________

PRODUCT RECALL CAMPAIGN

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: 97061(A) - PCV SYSTEM CHANGE

MODELS: 1995-97 CHEVROLET AND GMC W4 MODELS WITH DIESEL ENGINES

THIS BULLETIN CANCELS AND REPLACES BULLETIN 97061, ISSUED NOVEMBER, 1997 THE SERVICE PROCEDURE, PARTS INFORMATION, AND CLAIM INFORMATION HAS BEEN REVISED TO INCLUDE 1995 STRIPPED CHASSIS' ALL COPIES OF BULLETIN 97061 SHOULD BE DESTROYED

GENERAL MOTORS HAS DECIDED THAT CERTAIN 1995-97 CHEVROLET AND GMC W4 MODEL VEHICLES EQUIPPED WITH DIESEL ENGINES MAY EXHIBIT A CONDITION IN WHICH THE CLOSED SYSTEM DESIGN OF THE CURRENT PCV SYSTEM MAY ALLOW ENGINE OIL TO ENTER THE INTAKE SYSTEM IF THIS WERE TO OCCUR, ENGINE FAILURE OR PISTON MELTING MAY OCCUR

TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO CONVERT THE EXISTING PCV CLOSED SYSTEM INTO AN OPEN SYSTEM

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1995-97 W4 MODEL VEHICLES EQUIPPED WITH DIESEL ENGINES AND BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1995 CHEVROLET W4 FUJISAWA "7" S7000009 S7022402 1996 CHEVROLET W4 FUJISAWA "7" T7002296 T7009081 1997 CHEVROLET W4 FUJISAWA "7" V7000509 V7010831 1995 GMC W4 FUJISAWA "7" S7000012 S7022404 1996 GMC W4 FUJISAWA "7" T7002297 T7009171 1997 GMC W4 FUJISAWA "7" V7000002 V7010919

NOTICE: DEALERS SHOULD CONFIRM VEHICLE ELIGIBILITY THROUGH VISS (VEHICLE INFORMATION SERVICE SYSTEM) OR SERVICENET (GMC ONLY) 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

PARTS INFORMATION

PARTS REQUIRED TO COMPLETE THIS CAMPAIGN ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATIONS (GMSPO) PLEASE REFER TO YOUR "INVOLVED VEHICLES LISTING" PRIOR TO ORDERING REQUIREMENTS NORMAL ORDERS SHOULD BE PLACED ON A DRO = DAILY REPLENISHMENT ORDER AN EMERGENCY REQUIREMENT SHOULD BE ORDERED ON A CSO = CUSTOMER SPECIAL ORDER

IF THE VEHICLE IS A 1995 STRIPPED CHASSIS, ORDER INDIVIDUAL PARTS LISTED IN "STRIPPED CHASSIS ONLY" SECTION ON THE NEXT PAGE

PART NUMBER DESCRIPTION QUANTITY/VEHICLE

97720162 PCV OPEN SYSTEM KIT* 1 OR 97724168 PCV OPEN SYSTEM KIT* 1

12346286 SILICONE SEALER (LOCTITE 5900) 1 TUBE (14 APPLICATIONS/TUBE)

* THERE ARE ESSENTIALLY TWO PCV OPEN SYSTEM KITS AVAILABLE FOR PERFORMING THIS CAMPAIGN REPAIR THESE TWO KITS DIFFER ONLY IN THE TYPE OF OIL CATCH TANK BRACKET USED, AND THE HARDWARE NEEDED TO INSTALL IT TO THE AIR INTAKE DUCT BRACKET; AND IN THE TYPE OF HOSES SUPPLIED EITHER KIT HOWEVER, WILL EFFECTIVELY REPAIR ANY OF THE AFFECTED VEHICLES SUBJECT TO THIS CAMPAIGN BASED ON AVAILABILITY OF THE KITS, GMSPO MAY SUBSTITUTE KITS

1995 STRIPPED CHASSIS ONLY:

PART NUMBER DESCRIPTION QUANTITY/VEHICLE

97039773 OIL PAN 1 94370666 OIL PAN GASKET 1 94107678 OIL PIPE CAP (RUBBER CAP) 1 97721205 RUBBER HOSE CLIP (WORM HOSE CLAMP) 1 97065544 PRESSURE CONTROL VALVE CATCH TANK (OIL CATCH TANK) 1 94381356 OIL CATCH TANK BRACKET 1 94010893 AIR TANK BOLT (OIL CATCH TANK BRACKET RETAINING BOLT) 1 97039775 CHECK VALVE TO OIL PAN HOSE (OIL DRAIN HOSE) 1 94060447 RUBBER HOSE (BREATHER HOSE) 1 97016031 HEAD COVER TO COMMON CHAMBER HOSE (RUBBER PCV HOSE) 1 94238571 AIR HOSE CLIP (SMALL SPRING CLAMP-OIL DRAIN HOSE) 2 94242034 POWER STEERING HOSE CLIP (LARGE SPRING CLAMP-BREATHER HOSE, RUBBER PCV HOSE) 3 94149473 PCV HOSE CLIP (BREATHER HOSE RETAINING CLIP) 1 94008815 OIL PAN BOLT (BREATHER HOSE RETAINING CLIP BOLT) 1 97049282 OIL FILTER 1

CUSTOMER NOTIFICATION

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)

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 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 APPROPRIATE DIVISIONAL 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

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

SERVICE PROCEDURE

IF THE VEHICLE IS A 1995 STRIPPED CHASSIS, SKIP THIS SECTION AND PROCEED TO THE SERVICE PROCEDURE TITLED "1995 STRIPPED CHASSIS PCV SYSTEM CHANGE PROCEDURE"

IMPORTANT: BASED ON KIT AVAILABILITY, GMSPO MAY SUBSTITUTE PCV OPEN SYSTEM KITS BEFORE BEGINNING THIS SERVICE PROCEDURE, NOTE THE PART NUMBER OF THE KIT YOU HAVE RECEIVED

THERE ARE ESSENTIALLY TWO PCV OPEN SYSTEM KITS AVAILABLE FOR PERFORMING THE REPAIRS CALLED OUT IN THIS CAMPAIGN BULLETIN THESE TWO KITS DIFFER ONLY IN THE TYPE OF OIL CATCH TANK BRACKET USED, AND THE HARDWARE NEEDED TO INSTALL IT TO THE AIR INTAKE DUCT BRACKET; AND IN THE TYPE OF HOSES SUPPLIED EITHER KIT HOWEVER, WILL EFFECTIVELY REPAIR ANY OF THE AFFECTED VEHICLES SUBJECT TO THIS CAMPAIGN

ONE KIT, P/N 97720162, USES AN OIL CATCH TANK BRACKET WHICH IS INSTALLED USING NEW HARDWARE (BOLT, PLAIN WASHER, SPLIT WASHER, AND RETAINING NUT) SUPPLIED FROM THE KIT (FIGURE 1) HOSES SUPPLIED IN THE KIT ARE A COMBINATION OF STRAIGHT, PREFORMED, AND JOINED

THE OTHER KIT, P/N 97724168, USES A DIFFERENT STYLE OF OIL CATCH TANK BRACKET WHICH IS INSTALLED USING THE EXISTING HARDWARE (BOLT AND PLAIN WASHER) FROM THE AIR INTAKE DUCT BRACKET (FIGURE 1) ALL HOSES SUPPLIED IN THIS KIT ARE SINGLE-PIECE AND PREFORMED

DETAILED INSTRUCTIONS FOR THIS CAMPAIGN REPAIR ARE ALSO INCLUDED IN THE INSTALLATION INSTRUCTIONS PACKAGED WITH THE PCV OPEN SYSTEM KIT

FIGURE 1

1 SET THE PARKING BRAKE AND BLOCK THE WHEELS

2 DISCONNECT THE BATTERY GROUND CABLE

3 TILT THE CAB AND LOCK IT IN PLACE

4 REMOVE AND DISCARD THE EXISTING RUBBER PCV HOSE THAT CONNECTS FROM THE AIR INTAKE PIPE TO THE CYLINDER HEAD COVER

5 REMOVE THE EXISTING BOLT AND PLAIN WASHER FROM THE AIR INTAKE DUCT BRACKET

IMPORTANT: FOR KITS WITH P/N 97720162, DISCARD THE EXISTING BOLT AND PLAIN WASHER NEW HARDWARE IS SUPPLIED IN THE KIT

FOR KITS WITH P/N 97724168, RETAIN THE EXISTING BOLT AND PLAIN WASHER FOR REINSTALLATION LATER

6 REMOVE THE RETAINING BOLT AND WASHER FROM THE DIPSTICK TUBE BRACKET REMOVE AND DISCARD THE EXISTING DIPSTICK TUBE

IMPORTANT: BE SURE THE TWO O-RINGS ON THE LOWER END OF THE EXISTING DIPSTICK TUBE ARE NOT LEFT IN THE DIPSTICK TUBE OPENING IN THE CRANKCASE ALSO, BE SURE TO REMOVE AND SAVE THE EXISTING DIPSTICK BEFORE DISCARDING THE EXISTING DIPSTICK TUBE

7 INSTALL THE RUBBER CAP, SUPPLIED FROM THE KIT, TO THE AIR INTAKE PIPE SECURE THE RUBBER CAP TO THE AIR INTAKE PIPE USING THE WORM HOSE CLAMP SUPPLIED FROM THE KIT (FIGURE 2)

8 INSTALL THE NEW DIPSTICK TUBE, SUPPLIED FROM THE KIT, TO THE BRACKET USING THE EXISTING DIPSTICK TUBE WASHER AND RETAINING BOLT (FIGURE 3) TIGHTEN THE RETAINING BOLT 19 NM (14 FT LBS ) INSTALL THE EXISTING DIPSTICK INTO THE DIPSTICK TUBE

IMPORTANT: BE SURE TO APPLY A THIN COAT OF ENGINE OIL TO THE TWO O-RINGS ON THE LOWER END OF THE NEW DIPSTICK TUBE BEFORE INSTALLATION

FIGURE 2

FIGURE 3

9 INSTALL THE OIL CATCH TANK BRACKET, SUPPLIED FROM THE KIT, TO THE AIR INTAKE DUCT BRACKET (FIGURE 4A, 4B) SECURE THE OIL CATCH TANK BRACKET TO THE AIR INTAKE DUCT BRACKET

IMPORTANT: FOR KITS WITH P/N 97720162, USE THE NEW BOLT, PLAIN WASHER, SPLIT WASHER, AND RETAINING NUT SUPPLIED FROM THE KIT TIGHTEN THE NEW BOLT TO 40 NM (30 FT LBS )

FOR KITS WITH P/N 97724168, USE THE EXISTING BOLT AND PLAIN WASHER REMOVED EARLIER IN STEP 5 TIGHTEN THE EXISTING BOLT TO 40 NM (30 FT LBS )

FIGURE 4A

FIGURE 4B

10 WORKING FROM THE BACK OF THE ENGINE, INSERT ONE END OF THE OIL DRAIN RETURN HOSE ASSEMBLY, SUPPLIED FROM THE KIT, ACROSS INJECTOR NO 4, AND FEED IT UP TO THE OIL CATCH TANK BRACKET (FIGURE 5A, 5B) SLIP A SMALL SPRING CLAMP, SUPPLIED FROM THE KIT, OVER THE END OF THE OIL DRAIN RETURN HOSE ASSEMBLY AND INSERT THE HOSE END INTO THE FITTING ON THE BOTTOM OF THE OIL CATCH TANK, SUPPLIED FROM THE KIT SECURE THE HOSE END WITH THE SMALL SPRING CLAMP

IMPORTANT: FOR KITS WITH P/N 97720162, THE OIL DRAIN RETURN HOSE ASSEMBLY CONSISTS OF TWO FORMED HOSES JOINED TOGETHER

FOR KITS WITH P/N 97724168, THE OIL DRAIN RETURN HOSE ASSEMBLY CONSISTS OF ONE FORMED HOSE

INSTALLATION OF EITHER HOSE ASSEMBLY IS THE SAME

FIGURE 5A

FIGURE 5B

11 INSERT ONE END OF THE BREATHER HOSE, SUPPLIED FROM THE KIT, DOWN THROUGH THE OPENING BETWEEN THE INTAKE MANIFOLD AND THE FUEL FILTER BRACKET (FIGURE 6A); DOWN IN FRONT OF THE OIL FILTER-TO-OIL COOLER PIPE (FIGURE 6B, 6C); AND DOWN ALONGSIDE THE ENGINE BLOCK

FIGURE 6A

FIGURE 6B

FIGURE 6C

12 SLIP A LARGE SPRING CLAMP, SUPPLIED FROM THE KIT, OVER THE END OF THE BREATHER HOSE AND INSERT THE HOSE END INTO THE FITTING ON THE BOTTOM OF THE OIL CATCH TANK SECURE THE HOSE END WITH THE LARGE SPRING CLAMP

13 INSTALL THE OIL CATCH TANK ONTO THE OIL CATCH TANK BRACKET

IMPORTANT: FOR KITS WITH P/N 97720162, APPLY A BEAD OF LOCTITE 5900 SILICONE SEALER, OR EQUIVALENT, TO THE TOP EDGE OF THE OIL CATCH TANK BRACKET POSITION THE MOLDED SLOT ON THE BACK OF THE OIL CATCH TAN OVER THE OIL CATCH TANK BRACKET, AND PRESS DOWN FIRMLY ON THE OIL CATCH TANK UNTIL IT SEATS ON THE BRACKET ONCE THE OIL CATCH TANK IS FIRMLY SEATED ON THE BRACKET, BE SURE TO SLIDE THE OIL CATCH TANK AS FAR TO THE LEFT ON THE BRACKET AS POSSIBLE (AS VIEWED FROM THE REAR) THIS WILL ENSURE PROPER ALIGNMENT OF THE OIL CATCH TANK WITH THE CONNECTING HOSES INSTALLED TO IT LATER IN THIS PROCEDURE

FOR KITS WITH P/N 97724168, POSITION THE MOLDED SLOT ON THE BACK OF THE OIL CATCH TANK OVER THE OIL CATCH TANK BRACKET, AND PRESS DOWN FIRMLY ON THE OIL CATCH TANK UNTIL IT SEATS ON THE BRACKET

14 SECURE THE BREATHER HOSE TO THE TURBOCHARGER OUTLET WATER PIPE, USING A 10-INCH TIE STRAP SUPPLIED FROM THE KIT (FIGURE 7); THEN, SECURE THE BOTTOM END OF THE BREATHER HOSE TO THE INJECTION PUMP OIL FEED LINE, USING A 10-INCH TIE STRAP SUPPLIED FROM THE KIT (FIGURE 8)

FIGURE 7

FIGURE 8

15 SLIDE A SMALL SPRING CLAMP, SUPPLIED FROM THE KIT, ONTO THE REMAINING END OF THE OIL DRAIN RETURN HOSE ASSEMBLY AND INSERT THE HOSE END INTO THE OIL RETURN TUBE EXTENDING FROM THE LOWER PORTION OF THE DIPSTICK TUBE SECURE THE OIL DRAIN RETURN HOSE ASSEMBLY TO THE DIPSTICK TUBE WITH THE SMALL SPRING CLAMP (FIGURE 9A); THEN, SECURE THE OIL DRAIN RETURN HOSE ASSEMBLY TO THE TURBOCHARGER OIL FEED LINE, USING A 10-INCH TIE STRAP SUPPLIED FROM THE KIT (FIGURE 9B, 9C)

IMPORTANT: FOR KITS WITH P/N 97720162, THE OIL DRAIN RETURN HOSE ASSEMBLY CONSISTS OF TWO FORMED HOSES JOINED TOGETHER FOR KITS WITH P/N 97724168, THE OIL DRAIN RETURN HOSE ASSEMBLY CONSISTS OF ONE FORMED HOSE

INSTALLATION OF EITHER HOSE ASSEMBLY IS THE SAME

FIGURE 9A

FIGURE 9B

FIGURE 9C

16 SLIDE A LARGE SPRING CLAMP, SUPPLIED FROM THE KIT, ONTO EACH END OF THE RUBBER PCV HOSE, SUPPLIED FROM THE KIT INSERT ONE END OF THE RUBBER PCV HOSE INTO THE FITTING ON THE SIDE OF THE CYLINDER HEAD COVER AND SECURE IT WITH THE LARGE SPRING CLAMP INSERT THE OTHER END INTO THE FITTING ON TOP OF THE OIL CATCH TANK AND SECURE IT WITH THE LARGE SPRING CLAMP (FIGURE 10)

FIGURE 10

17 RECONNECT THE BATTERY GROUND CABLE AND LOWER THE CAB

18 REMOVE WHEEL BLOCKS

19 INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL

1995 STRIPPED CHASSIS PCV SYSTEM CHANGE PROCEDURE

1 SET THE PARKING BRAKE AND BLOCK THE WHEELS

2 DISCONNECT THE BATTERY GROUND CABLE

3 DRAIN THE ENGINE OIL INTO A SUITABLE CONTAINER AND REPLACE THE OIL FILTER, P/N 9704282 REFER TO PAGE 6A6-12 OF THE 1995 W4 (NPR) SERVICE MANUAL (IST- SVC-4541) FOR DETAILS

4 REMOVE THE ENGINE MOUNT BRACKET BOLTS; THEN, REMOVE THE ENGINE MOUNT CROSSMEMBER

5 REMOVE THE OIL PAN RETAINING BOLTS; THEN REMOVE AND DISCARD THE EXISTING OIL PAN AND GASKET

6 APPLY GASKET SEALER TO THE CYLINDER BLOCK AT THE POINTS WHERE THE FRONT AND REAR MAIN BEARING CAPS AND OIL SEAL RETAINERS MEET THE OIL PAN GASKET FLANGE OF THE CYLINDER BLOCK

7 INSTALL THE NEW OIL PAN GASKET, P/N 94370666, TO THE CYLINDER BLOCK

8 INSTALL THE NEW OIL PAN, P/N 97039773, TO THE CYLINDER BLOCK AND SECURE IT WITH THE OIL PAN RETAINING BOLTS TIGHTEN THE RETAINING BOLTS TO 20 NM (15 FT LBS ) EACH

9 REINSTALL THE ENGINE MOUNT CROSSMEMBER TIGHTEN THE 10 MM RETAINING BOLTS TO 66 NM (48 FT LBS ); AND THE 12 MM RETAINING BOLTS TO 103 NM (76 FT LBS )

10 REINSTALL THE ENGINE MOUNT RETAINING BOLTS TIGHTEN THE BOLTS TO THE CROSSMEMBER TO 38 NM (28 FT LBS ); AND THE BOLTS TO THE CYLINDER BODY TO 41 NM (30 FT LBS )

11 REMOVE THE ENGINE COVER; THEN, REMOVE AND DISCARD THE EXISTING RUBBER PCV HOSE THAT CONNECTS FROM THE AIR INTAKE PIPE TO THE CYLINDER HEAD COVER

IMPORTANT: THE ENGINE COVER CONFIGURATION VARIES, DEPENDING UPON THE BODY MANUFACTURER DESIGN

NOTICE: WHEN WORKING INSIDE THE VEHICLE'S INTERIOR, BE VERY CAREFUL NOT TO DAMAGE OR SOIL CARPETS, SEATS, ETC THIS APPLIES PARTICULARLY TO MOTOR HOMES

12 INSTALL THE RUBBER CAP, P/N 94107678, TO THE AIR INTAKE PIPE (FIGURE 11) SECURE THE RUBBER CAP TO THE AIR INTAKE PIPE USING A WORM HOSE CLAMP, P/N 97721205

IMPORTANT: FOR STEPS 13 THROUGH 19 BELOW, REFER TO FIGURE 12 FOR DETAILS

13 REMOVE AND DISCARD THE LEFT RETAINING BOLT FOR THE OIL FILTER ADAPTER INSTALL THE OIL CATCH TANK BRACKET, P/N 94381356, TO THE OIL FILTER ADAPTER AND SECURE IT USING THE OIL CATCH TANK RETAINING BOLT, P/N 94010893 TIGHTEN THE RETAINING BOLT TO 40 NM (30 FT LBS)

14 SLIP A SMALL SPRING CLAMP, P/N 94238571, OVER THE END OF THE OIL DRAIN HOSE, P/N 97039775, AND INSERT THE HOSE END INTO THE SMALL FITTING ON THE BOTTOM OF THE OIL CATCH TANK, P/N 97065544 SECURE THE HOSE END WITH THE SMALL SPRING CLAMP

15 SLIP A LARGE SPRING CLAMP, P/N 94242034, ONTO ONE END OF THE BREATHER HOSE, P/N 94060447, AND INSERT THE BREATHER HOSE INTO THE LARGE FITTING ON THE BOTTOM OF THE OIL CATCH TANK SECURE THE HOSE END WITH THE LARGE SPRING CLAMP

16 POSITION THE MOLDED SLOT ON THE BACK OF THE OIL CATCH TANK OVER THE OIL CATCH TANK BRACKET, AND PRESS DOWN FIRMLY ON THE OIL CATCH TANK UNTIL IT SEATS ON THE BRACKET

17 SLIDE A SMALL SPRING CLAMP, P/N 94238571, ONTO THE REMAINING END OF THE OIL DRAIN HOSE AND INSERT THE HOSE END INTO THE TUBE EXTENDING FROM THE OIL PAN SECURE THE OIL DRAIN HOSE TO THE OIL PAN TUBE USING THE SMALL SPRING CLAMP

18 MOUNT THE BREATHER HOSE RETAINING CLIP, P/N 94149473, ONTO THE MOUNTING BRACKET ON THE OIL PAN AND SECURE IT WITH THE BREATHER HOSE RETAINING CLIP BOLT, P/N 94008815 TIGHTEN THE RETAINING CLIP BOLT TO 8 NM (6 FT LBS) CLIP THE LOWER END OF THE BREATHER HOSE INTO THE RETAINING CLIP

19 SLIDE A LARGE SPRING CLAMP, P/N 94242034, ONTO EACH END OF THE PRE-FORMED RUBBER PCV HOSE, P/N 97016031 INSERT ONE END OF THE RUBBER PCV HOSE INTO THE FITTING ON THE SIDE OF THE CYLINDER HEAD COVER AND SECURE IT WITH THE LARGE SPRING CLAMP INSERT THE OTHER END INTO THE FITTING ON TOP OF THE OIL CATCH TANK AND SECURE IT WITH THE LARGE SPRING CLAMP

20 REPLENISH THE ENGINE OIL REFER TO PAGE 6A6-12 OF THE SERVICE MANUAL FOR DETAILS WHEN COMPLETED, REINSTALL THE ENGINE COVER

IMPORTANT: BE SURE THAT THE OIL YOU USE HAS THE API DESIGNATION "CD" EITHER ALONE OR SHOWN WITH OTHER DESIGNATIONS SUCH AS "SF/CD" VISCOSITY RECOMMENDATIONS FOR VARIOUS STARTING TEMPERATURES ARE SHOWN IN THE SERVICE MANUAL, PAGE 0B-2

21 RECONNECT THE BATTERY GROUND CABLE AND REMOVE THE WHEEL BLOCKS

22 INSTALL THE GM CAMPAIGN IDENTIFICATION LABEL

FIGURE 11

FIGURE 12

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 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 A M TO 4:30 P M EST) ASK FOR ITEM NUMBER S-1015 WHEN ORDERING

APPLY THE "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW:

PART FAILED PARTS LABOR LABOR NET REPAIR PERFORMED COUNT PART NO. ALLOW CC-FC OP * HOURS ITEM

INSTALL PCV OPEN SYSTEM KIT 1 --- ** MA-96 V0102 0 3 $0 84 (A)

INSTALL PCV OPEN SYSTEM KIT - 1995 STRIPPED CHASSIS ONLY 14 --- ** MA-96 V0165 2 3 $24 00 (B)

* FOR CAMPAIGN ADMINISTRATIVE ALLOWANCE, ADD 0 1 HOURS TO THE "LABOR HOURS"

** THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 40% FOR PARTS NEEDED TO COMPLETE THE REPAIR

*** THE AMOUNT IDENTIFIED IN THE "NET ITEM" COLUMN REPRESENTS THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 40% FOR THE (A) SILICONE SEALER, OR (B) ENGINE OIL NEEDED TO PERFORM THE REQUIRED REPAIRS

REFER TO THE GENERAL MOTORS CORPORATION CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION

FIGURES: 18

GM BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER" THEY ARE WRITTEN TO INFORM THESE 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 TOOLS, EQUIPMENT, 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 YOUR DEALER/RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

97061

(SAMPLE OF NOTIFICATION USED)

NOVEMBER, 1997

DEAR CHEVROLET/GMC CUSTOMER:

THIS NOTICE IS SENT TO INFORM YOU OF A RECALL CAMPAIGN THAT INCLUDES YOUR VEHICLE

REASON FOR THIS RECALL: GENERAL MOTORS HAS DECIDED THAT CERTAIN 1995-97 CHEVROLET AND GMC W4 MODEL VEHICLES EQUIPPED WITH DIESEL ENGINES MAY EXHIBIT A CONDITION IN WHICH THE CLOSED SYSTEM DESIGN OF THE CURRENT PCV SYSTEM MAY ALLOW ENGINE OIL TO ENTER THE INTAKE SYSTEM IF THIS WERE TO OCCUR, ENGINE FAILURE OR PISTON MELTING MAY OCCUR

WHAT WILL BE DONE: TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, YOUR DEALER WILL CONVERT THE EXISTING PCV CLOSED SYSTEM INTO AN OPEN SYSTEM THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE

CONTACTING YOUR DEALER: PLEASE CONTACT YOUR DEALER AS SOON AS POSSIBLE TO ARRANGE A SERVICE DATE AND TO ASSURE PARTS AVAILABILITY 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 YOU EXPERIENCE ANY TROUBLE SCHEDULING YOUR VEHICLE OR YOU HAVE ANY QUESTIONS REGARDING THIS RECALL ACTION, PLEASE CONTACT THE APPROPRIATE CUSTOMER ASSISTANCE CENTER AT THE LISTED NUMBER BELOW:

DIVISION

NUMBER DEAF, HEARING IMPAIRED OR SPEECH IMPAIRED *

CHEVROLET 1-800-222-1020 1-800-833-2438

GMC 1-800-462-8782 1-800-462-8583

* UTILIZES TELECOMMUNICATION DEVICES FOR THE DEAF/TEXT TELEPHONES (TDD/TTY)

CUSTOMER REPLY CARD: THE ENCLOSED CUSTOMER 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 NO LONGER OWN THIS 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

CHEVROLET/PONTIAC-GMC DIVISION GENERAL MOTORS CORPORATION ENCLOSURE

COPYRIGHT 1998 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED