CAMPAIGN: QUAD 4 IGNITION COIL INSPECT COIL CASE FOR CRACKS

Subject: PRODUCT EMISSION CAMPAIGN 90C33 QUAD 4 IGNITION COIL

Model and Year: 1990 BERETTA GTZ WITH 2.3L H/O L4 ENGINE (ENGINE VIN CODE "A")

TO: ALL CHEVROLET DEALERS

General Motors has determined that certain 1990 Chevrolet Beretta GTZ model vehicles equipped with 2.3L H/O L4 engines (VIN Code "A") may develop cracks in the case of the IDI (Integrated Direct Ignition) coil(s) at high voltage terminals. As the cracks multiply, external arcing occurs between terminals and/or terminal to coil frame resulting in intermittent misfire, rough idle and ultimately a "no start" condition when the coil fails completely.

To prevent this condition from occurring, dealers are to inspect ignition coils on involved vehicles and, if necessary, replace the coils.

VEHICLES INVOLVED

Involved are certain 1990 Chevrolet Beretta GTZ model vehicles equipped with 2.3L H/O L4 engines and built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- --------- ---- -------- -------- 1990 L-Car Wilmington "Y" LY100005 LY227076 (GTZ Models)

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

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 required correction according to instructions contained in this bulletin.

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 ---------- --------------------- -------- 10457062 Ignition Coil Kit - 1 Kit Each Kit Contains 2 IDI Ignition Coils

SERVICE PROCEDURE

1. Raise and support hood.

2. Write down owner's preset radio stations and other memory functions that can be recorded and reset later; then with ignition in "off" position, disconnect negative battery cable from battery. If a memory retention device such as Kent-Moore tool KS295A is used, it is not necessary to record memory functions.

3. DO NOT disconnect 11 pin IDI harness connector.

4. Remove four bolts attaching ignition system assembly to cam housing.

5. Remove ignition system assembly from engine. Turn it upside down and lay it on engine using two (2) bolts as "locator pins" through cover into cam housing on "rear side" of engine to hold ignition system assembly in place.

NOTICE: If boots adhere to spark plugs, use tool J-36011 to remove them by first twisting and then pulling upward on retainers. Reinstall boots and retainers on IDI housing secondary terminals, making certain that spark plug connectors (Fig. 1, 9) are in place. Boots and retainers must be in place on IDI housing secondary terminals prior to ignition system unit installation or ignition system damage may result.

6. Remove four housing to cover screws (Fig. 1, 4) and remove ignition coil housing (Fig. 1, 7) from cover (Fig. 1, 1).

7. Remove coil harness connectors (Fig. 1, 5) from coils.

8. Refer to Figure 2 and inspect two ignition coils for color of electric tab. Ignition coils with black electrical tabs are to be replaced with new coils (from kit) having yellow electrical tabs. Coils with yellow electrical tabs do not require replacement. It should be rare to find a campaign vehicle in which one or both coils already have yellow tabs.

9. If necessary to replace one or both coils, remove "black tab" coil (s) , contact (s) and seal (s) f rom cover (See Fig. 1, items 6, 13 & 14).

10. Reinstall seal(s) (Fig. 1, 14) to housing.

11. Reinstall contact(s) (Fig. 1, 13) to housing (use petroleum jelly to retain).

12. Install new "yellow tab" coil(s) to cover, as required. Install coil harness connectors to both coils.

13. Reinstall housing (Fig. 1, 7) to cover (Fig. 1, 1) with four screws (Fig. 1, 4) and torque screws to 4 Nm. (35 lb. in.).

14. Install ignition system assembly to engine while carefully aligning boots to spark plug terminals.

15. Coat the four (4) ignition system assembly to cam housing bolts with P/N 1052080 sealer (or equivalent). Install bolts through cover to cam housing and torque to 20 Nm. (15 lb. ft.).

NOTICE: If these bolts are not coated with sealer prior to reinstallation, future removal of bolts may strip threads in aluminum of cam housings.

16. Reconnect negative battery cable. In interest of customer satisfaction, please reset (to extent possible) all devices which lost memory after the battery was disconnected (not required if memory tool was used).

17. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include 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. 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 REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS ------------------- -- -------- ----- ----- ----- --- --- Inspect - No Coils SK-00 V6510 0.3 0.1 Need Replacement

Inspect/Replace One 1 10457062 ** SK-00 V6511 0.3 0.1 Or Both Coil(s)

Inspect Owners Repair Order - Ignition SK-00 V6512 0.2 0.1 Coil Prev. Replaced

Reimbursement For Previous Cracked VE-95 T4680 Ignition Coil Repair

* 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 on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

REIMBURSEMENT

Customer requests for reimbursement of prior replacement of the ignition coil(s) due to misfire, rough idle or a "no start" condition are to be submitted according to the instructions in this bulletin using the attached "Request For Reimbursement" form (additional copies to be reproduced locally). owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, description of the repair, date of repair, and the person or entity performing the repair.

NOTICE: When a customer requests reimbursement, and the vehicle is still available, dealers are to inspect and, if necessary, replace ignition coils as called for in the SERVICE PROCEDURE section of this bulletin. If owner documentation indicates that both coils were replaced using coils from kit P/N 10457062 (or two P/N 10472748 coils), Labor Operation V6512 may be applied for and it is not necessary to physically inspect the involved vehicle. Until the involved vehicle is confirmed to have new coils installed (by inspection of vehicle or repair order, and any necessary coil replacements performed), the campaign must remain open regardless of any reimbursement.

REQUEST FOR REIMBURSEMENT INSTRUCTIONS PRODUCT EMISSION CAMPAIGN 90C33 (QUAD 4 IGNITION COIL - 1990 BERETTA GTZ)

1 R.O. # & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice.

2 REQUEST DATE (MONTH, DAY) Date owner or dealer requested reimbursement.

3 VEHICLE IDENTIFICATION NUMBER VIN involved.

4 MILEAGE Enter mileage at time of transaction. (If not available, enter "0".)

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation as referenced in bulletin.

7 & 8 SUBLET DMN & Enter total amount of reimbursement. (Do LINE TOTAL not enter parts or labor hours on claim.)

9 AUTH CODE If the amount of reimbursement approved is $200 or less, no authorization is needed. If the amount exceeds $200, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.

10 REQUESTED Dealer Service Manager enter amounts REIMBURSEMENT determined from owner supplied invoices or paid receipts, which are covered. (Maximum amount is $200.)

11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. (Maximum amount is $200.)

12 740 STAMP Dealer Service Manager is to stamp reimbursement form including date and signature. (No Authorization Code is required.)

13 DEALER REFERENCE INFORMATION A Enter Document Number & Line Number on which claim was submitted.

B Enter Claim Memo Number and Date when claim is credited.

C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER INFORMATION Must include telephone number.

15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.

16 EXPLAIN Should the dealer Service Manager determine, after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the file.

17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.

Dear Chevrolet Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting an emission recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1990 Chevrolet Beretta GTZ model vehicles equipped with 2.3L H/O L4 engines may develop cracks in the case of the IDI (Integrated Direct Ignition) coil(s) at the high voltage terminals. As the cracks multiply, external arching occurs between terminals and/or terminal to coil frame resulting in intermittent misfire, rough idle and ultimately a "no start" condition when the coil fails completely.

WHAT WE WILL DO

To prevent this condition from occurring, your dealer will inspect your vehicle's ignition coils and, if necessary, replace the coils. This service will be provided for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

If your Chevrolet Beretta GTZ previously had the ignition coil(s) replaced for a misfire, rough idle or "no start" condition, and you paid for all or part of the repair, you may request reimbursement through your Chevrolet dealer. When doing so, you should present the dealer with original documentation which reasonably confirms the amount of unreimbursed repair expenses due to replacement/repair of the ignition coil(s), date of the repair, and the person or entity performing the repair. You should also have your dealer inspect your vehicle to see if the campaign work still needs to be performed, regardless of prior repairs for a misfire, rough idle or "no start" condition.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Should your dealer not schedule a service date within a reasonable time, you should contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

If your dealer and the Customer Assistance Center are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturer's Operations Division (EN-340F), United States Environmental Protection Agency, 401 M Street. S.W., Washington, D.C. 20460.

To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if this recall work is not accomplished.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your 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.