CAMPAIGN: (SAFETY) POWER STEERING HOSE ROUTING

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.

IN ORDER TO AVOID HAVING TO PROVIDE THESE BURDENSOME SOLUTIONS, EVERY EFFORT MUST BE MADE TO PROMPTLY SCHEDULE AN APPOINTMENT WITH EACH OWNER AND TO REPAIR HIS VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER WHICH IS BEING SENT TO OWNERS, THE OWNER IS BEING INSTRUCTED TO CONTACT THE NEAREST CHEVROLET ZONE OFFICE IF HIS 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, HE IS INSTRUCTED ON HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFICE SAFETY ADMINISTRATION.

DEFECT INVOLVED

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN SOME 1981 CHEVROLET CITATION MODELS EQUIPPED WITH A V6 ENGINE AND POWER STEERING. THE INVOLVED VEHICLES MAY HAVE BEEN ASSEMBLED WITH THE POWER STEERING HOSE(S) INCORRECTLY ROUTED. IF THIS CONDITION IS NOT CORRECTED THE POWER STEERING HOSE MAY CONTACT THE EXHAUST MANIFOLD, RESULTING IN POSSIBLE DETERIORATION OF THE HOSE. HOSE FAILURE WOULD RESULT IN POWER STEERING FLUID LEAKAGE ONTO THE EXHAUST MANIFOLD. UNDER CERTAIN CONDITIONS SMOKE AND/OR AN UNDERHOOD FIRE COULD THEN RESULT. SUCH A FIRE COULD, IN TIME SPREAD TO THE PASSENGER COMPARTMENT AND CAUSE BURN INJURIES TO OCCUPANTS REMAINING IN THE VEHICLE.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1981 CHEVROLET CITATION MODELS EQUIPPED WITH A V6 ENGINE AND POWER STEERING AND ARE WITHIN THE FOLLOWING VEHICLE BREAKPOINTS:

PLANTS FROM THROUGH

WILLOW RUN START OF PRODUCTION 1G1AX68X9BW106797 TARRYTOWN START OF PRODUCTION 1G1AX68X2BT112054 OKLAHOMA CITY START OF PRODUCTION 1G1AX68XXB6115489

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, 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.

ALL INVOLVED VEHICLES THAT ARE IN DEALER INVENTORY ARE NOT TO BE SOLD BY THE DEALER UNTIL THIS CAMPAIGN MODIFICATION HAS BEEN COMPLETED.

DEALERS SHOULD IMMEDIATELY REVIEW THEIR LISTINGS AGAINST DEALER RECORDS ON "STOCK" UNITS WHERE THE OWNER NAME AND ADDRESS WAS UNKONWN TO CHEVROLET AT THE TIME OF CAMPAIGN ANNOUNCEMENT. DEALERS SHOULD IMMEDIATELY CONTACT THESE OWNERS FOR THE APPROPRIATE CAMPAIGN MODIFICATION.

SERVICE PROCEDURE

SELECT APPLICABLE SERVICE PROCEDURE FROM THOSE NOTED BELOW BASED ON WHETHER THE VEHICLE IS EQUIPPED WITH OR WITHOUT AIR CONDITIONING (C60).

SERVICE PROCEDURE AIR CONDITIONED VEHICLES: 1. INSPECT POWER STEERING RETURN HOSE ROUTING AND DETERMINE IF CLEARANCE BETWEEN THE RETURN HOSE AND EXHAUST MANIFOLD IS AT LEAST 40MM (1-9/16 INCHES). (REFERENCE VIEW C)

2. DISCONNECT BOTH THE STEERING GEAR RETURN PIPE AND PRESSURE HOSE ASSEMBLIES AT THE POWER STEERING RACK AND PINION GEAR (VIEW A).

NOTICE: IF HOSES ARE SECURED TO THE A/C ACCUMULATOR REFRIGERANT TUBE WITH A PLASTIC BAND, CUT AND DISCARD THE BAND.

3. DISCONNECT THE PRESSURE HOSE ASSEMBLY AT THE PRSSURE SENSING SWITCH/ OR CONNECTOR AND DISCARD.

4. INSTALL NEW PRESSURE HOSE ASSEMBLY, P/N 7839065 ROUTING THE HOSE BEHIND THE HEATER HOSE AS SHOWN IN VIEW B AND TORQUE FITTINGS TO 28 NM (20 FT. LBS.).

5A. CLEARANCE DETERMINED IN STEP 1 40MM (1-9/16 INCHES) OR GREATER. RECONNECT THE STEERING GEAR RETURN PIPE ASSEMBLY, POSITIONING THE PIPE AS SHOWN IN VIEW A, TORQUE FITTING TO 28 NM (20 FT. LBS.) AND PROCEED TO STEP 8.

5B. CLEARANCE DETERMINED IN STEP 1 LESS THAN 40MM (1-9/16 INCHES). DISCONNECT RETURN HOSE AT THE RETURN PIPE ASSEMBLY (ENGINE MOUNTED) AND DISCARD THE HOSE AND STEERING GEAR RETURN PIPE ASSEMBLY.

6. CUT NEW HOSE, P/N 7828506, TO A LENGTH OF 16 INCHES AND SECURE TO NEW STEERING GEAR RETURN PIPE ASSEMBLY, P/N 14036321, UTILIZING CLAMP, P/N 2494772. INSTALL NEW O RING P/N 7829923 TO STEETING GEAR RETURN PIPE ASSEMBLY.

7. ROUTE AND POSITION NEW HOSE AND RETURN PIPE ASSEMBLY AS SHOWN IN VIEW A AND B, TORQUE FITTING AT THE STEERING GEAR TO 28 NM (20 FT.LBS.) AND SECURE HOSE TO THE RETURN PIPE ASSEMBLY (ENGINE MOUNTED) WITH CLAMP P/N 2494772.

8. BLEED SYSTEM FOLLOWING SHOP MANUAL PROCEDURE (REFERENCE 1980 CITATION SHOP MANUAL, PAGE 3B2-5).

9. ELEVATE VEHICLE AND REMOVE RIGHT FRONT WHEEL AND TIRE ASSEMBLY.

10. UTILIZING A ROUND FILE REMOVE THE TWO RETENTION RIDGES ON CLIP, P/N 12010445 (REFERENCE VIEW C).

11. GAINING ACCESS THROUGH THE RIGHT FRONT WHEEL WELL, POSITION ALTERED CLIP, P/N 12010445, BETWEEN THE PRESSURE AND RETURN PIPE ASSEMBLIES AS SHOWN IN VIEW C AND LOCK CLIP IN POSITION. 12. REINSTALL RIGHT FRONT WHEEL AND TIRE ASSEMBLY, TORQUING LUG NUTS TO 125 NM (90 FT.LBS.) AND LOWER VEHICLE.

13. REINSPECT AND VERIFY PRESSURE AND RETURN HOSE ROUTINGS AND CLEARANCE AS NOTED BELOW:

A. PRESSURE HOSE TO ACCUMULATOR REFRIGERANT TUBE CLEARNACE 5MM (7/32 INCH)(REFERENCE VIEW B). NOTICE: IF REQUIRED, BEND THE PRESSURE PIPE ASSEMBLY DOWN AND FORWARD AT THE ENGINE MOUNTED RETAINING CLIP TO OBTAIN REQUIRED CLEARANCE. B. RETURN PIPE ASSEMBLY TO ENGINE PIPE RETAINING BRACKET POSITION 75MM (3 INCHES)(REFERENCE VEIW VIEW C AND D). C. RETURN HOSE TO PRESSURE AND RETURN PIPE ASSEMBLIES (ENGINE MOUNTED) 5MM (7/32 INCHE)(REFERENCE VIEW C). NOTICE: IF REQUIRED, BEND THE RETURN PIPE ASSEMBLY UPWARD AT THE ENGINE MOUNTED RETAINING CLIP TO OBTAIN REQUIRED CLEARANCE.

SERVICE PROCEDURE NON-AIR CONDITIONED VEHICLES:

1. INSPECT POWER STEERING PRESSURE HOSE ROUTING AND IF CLEARANCE BETWEEN HOSE AND EXHAUST MANIFOLD IS LESS THAN 40MM (1-9/16 INCHES), PROCEED TO AND FOLLOW SERVICE PROCEDURE FOR AIR CONDITIONED VEHICLES. (REFERENCE VIEW C)

2. INSPECT POWER STEERING RETURN HOSE ROUTING AND IF CLEARANCE BETWEEN HOSE AND EXHAUST MANIFOLD IS 40MM (1-9/16 INCHES) OR MORE, PROCEED TO STEP 7 (REFERENCE VIEW C).

3. DISCONNECT THE RETURN HOSE AND STEERING GEAR PIPE ASSEMBLY AND DISCARD.

4. CUT NEW HOSE, P/N 7828506,TO A LENGTH OF 16 INCHES AND SECURE TO NEW STEERING GEAR RETURN PIPE ASSEMBLY, P/N 14036321, UTILIZING CLAMP, P/N 2494772. INSTALL NEW O RING, P/N 7829923 TO STEERING GEAR RETURN PIPE ASSEMBLY.

5. ROUTE AND POSITION NEW HOSE AND RETURN PIPE ASSEMBLY AS SHOWN IN VIEW A AND B, TORQUE FITTING AT THE STEERING GEAR TO 28 NM (20 FT.LBS.) AND SECURE HOSE TO THE RETURN PIPE ASSEMBLY (ENGINE MOUNTED) WITH CLAMP P/N 2494772.

6. BLEED SYSTEM FOLLOWING SHOP MANUAL PROCEDURE (REFERENCE 1980 CITATION SHOP MANUAL, PAGE 3B2-5.)

7. ELEVATE VEHICLE AND REMOVE RIGHT FRONT WHEEL AND TIRE ASSEMBLY.

8. UTILIZING A ROUND FILE REMOVE THE TWO RETENTION RIDGES ON CLIP, P/N 12010445 (REFERENCE VIEW C).

9. GAINING ACCESS THROUGH THE RIGHT FRONT WHEEL WELL, POSITION ALTERED CLIP, P/N 12010445, BETWEEN THE PRESSURE AND RETURN PIPE ASSEMBLIES AS SHOWN IN VIEW C AND LOCK CLIP IN POSITION.

10. REINSTALL RIGHT FRONT WHEEL AND TIRE ASSEMBLY, TORQUING LUG NUTS TO 125 NM (90 FT.LBS.) AND LOWER VEHICLE.

11. REINSPECT AND VERIFY PRESSURE AND RETURN HOSE ROUTINGS AND CLEARANCES AS NOTED BELOW:

A. RETURN PIPE ASSEMBLY TO ENGINE PIPE RETAINING BRACKET POSITION 75MM (3 INCHES)(REFERENCE VIEW C AND D). B. RETURN HOSE TO PRESSURE AND RETURN PIPE ASSEMBLIES (ENGINE MOUNTED) 5MM (7/32 INCH)(REFERENCE VIEW C).

NOTICE: IF REQUIRED, BEND THE RETURN PIPE ASSEMBLY UPWARD AT THE ENGINE MOUNTED RETAINING CLIP TO OBTAIN REQUIRED CLEARANCE.

PARTS INFORMATION

THE FOLLOWING PARTS, IDENTIFIED WITH AN (*ASTERISK) ARE TO BE OBTAINED FROM YOUR CHEVROLET ZONE SERVICE DEPARTMENT AND WILL BE FURNISHED ON A NO CHARGE BASIS.

PART NUMBER 2494772 HOSE CLAMPS, 7828506 POWER STEERING RETURN HOSE AND POWER STEERING FLUID ARE TO BE OBTAINED FROM DEALER STOCK.

PART NUMBER QUANTITY PER VEHICLE DESCRIPTION WHEN REQUIRED 2494772 2 SCREW TYPE HOSE CLAMPS 7828506 (10 FT.ROLL) 1(16" PIECE) P/S RETURN HOSE *22501281 1 INLET PIPE *12010445 1 PLASTIC CLIP *7839065 1 P/S PRESSURE HOSE *7829923 1 "O" RING

PART NUMBERS IDENTIFIED WITH AN (*ASTERISK) ARE NOT TO BE ORDERED OR RETURNED TO GENERAL MOTORS PARTS DIVISION.

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAGIN CLAIM WITH THE INFORMATION INDICATED BELOW:

PARTS FAILED **PARTS FAILURE LABOR LABOR *OTHER COUNT PART NO. ALLOWANCE CODE OPERATION HOURS HOURS

1 12010445 .08 00 V0560 .4 .1

DESCRIPTION: V6 ENGINE, POWER STEERING WITHOUT A/C. INSPECT BOTH PRESSURE AND RETURN POWER STEERING HOLES AND INSTALL PLASTIC CLIP ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. NO FURTHER ACTION REQUIRED.

6 72828506 4.17 00 V0561 .6 .1

DESCRIPTION: V6 ENGINE, POWER STEERING WITHOUT A/C. INSPECT POWER STEERING PRESSURE HOSE, REPLACE POWER STEERING RETURN HOSE AND INSTALL PLASTIC CLIP ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN.

7 7839065 10.51 00 V0562 .8 .1

DESCRIPTION: V6 ENGINE, POWER STEERING WITHOUT A/C. INSPECT AND REPLACE BOTH PRESSURE AND RETURN POWER STEERING HOSES, INSTALL PLASTIC CLIP ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN.

2 7839065 6.72 00 V0563 .8 .1

DESCRIPTION: V6 ENGINE, POWER STEERING WITH A/C. INSPECT POWER STEERING RETURN HOSE, REPLACE POWER STEERING PRESSURE HOSE, INSTALL PLASTIC CLIP ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN.

7 7839065 10.51 00 V0564 .8 .1

DESCRIPTION: V6 ENGINE, POWER STEERING WITH A/C. INSPECT AND REPLACE BOTH POWER STEERING PRESSURE AND RETURN HOSES, INSTALL PLASTIC CLIP ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS BULLETIN.

* CAMPAIGN ADMINISTRATIVE ALLOWANCE

** 30% OF DEALER NET ONLY FOR PARTS FURNISHED AT NO CHARGE BY CHEVROLET.

DEALERS WILL AUTOMATICALLY RECEIVE THE CORRECT PARTS AND LABOR ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED. AMOUNTS ARE ENTERED ON CAMPAIGN CLAIMS TO ALLOW THE DEALER TO DEVELOP AN ACCOUNTS RECEIVABLE AMOUNT ONLY.

THIS ADJUSTMENT WILL LIKEWISE REFLECT AN APPLICABLE AMOUNT FOR POWER STEERING FLUID AND HOSE CLAMPS WHEN USED WHERE APPLICABLE.

REFER TO THE CHEVROLET PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE MODIFIED 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 BY 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.

ADMINISTRATIVE PROCEDURE

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

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.