CAMPAIGN: INSTRUMENT PANEL WIRE ABRASION -REPAIR. Chevrolet Corvette 1990

Models: 1990 Chevrolet Corvette W/L98 or LT5 Engine

TO: ALL AFFECTED DEALERS:

General Motors of Canada has determined that certain 1990 Chevrolet Corvette model vehicles with L98 or LT5 engines may experience instrument panel wires rubbing on the hood release cable bracket causing abrasion of the instrument panel wiring. If this condition continues to exist, the instrument panel wiring may wear through its covering and ground itself on the hood release cable bracket causing a short in the vehicle's electrical system and an inoperable vehicle engine.

In order to prevent the possibility of this condition occurring, dealers should apply 3M Brand, or equivalent, Electrical Moisture Sealant Tape to the instrument panel wiring and hood release cable bracket, thus protecting the instrument panel wires from abrasion. Additionally, instrument panel wiring which shows signs of abrasion should be repaired.

VEHICLES INVOLVED:

Involved are certain 1990 Chevrolet Corvette model vehicles with L98 or LT5 engines built within the following VIN breakpoints:

MODEL/YEAR PLANT FROM THROUGH ---------- ----- ---- -------- Y 1990 Bowling Green L5100001 L5103172

Y 1990 Bowling Green L5800001 L5800227

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

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 modification according to instructions contained in this bulletin.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose. Some owners will receive letters addressing more than one campaign on their vehicle (see copies of owner letters included with this bulletin) as shown in the chart below.

VIN Range Campaigns Addressed In Owner Letters ---------- ------------------------------------ L5800121 - L5800213 0R02 / 0A07

L5800214 - L5800227 0R02

L5100001 - L5100887 0R02 / 0R03

L5100888 - L5103172 0R02

PARTS INFORMATION:

Parts required to complete this campaign are to be obtained from the dealer's 3M supplier (or equivalent material supplier).

Part Number Description Quantity/Vehicle ----------- ----------- ----------------- 06147 (3M Part 3M Brand Electrical Approx. 2.5 ft. Moisture Sealant Tape (or equivalent)

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card, RAPID terminal or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Inspect and Apply Sealant Tape .7

3A Inspect, Repair Wires and .9 Apply Sealant Tape

An amount of $5.00 has been included in Repair Code 2A and 3A to cover the cost plus 30% for 3M Brand Electrical Moisture Sealant Tape.

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign.

SERVICE PROCEDURE:

1. Remove left-hand lower trim pad assembly, knee bolster pad, and A/C duct from driver's side of vehicle to gain access to instrument panel wiring harness (hereafter I/P harness).

2. Inspect I/P harness, at the point at which it routes past the hood release cable bracket, for any wire abrasion. If any wires are damaged, repair them using proper splicing techniques as described in Section 8A of the 1990 Corvette Service Manual.

3. Apply 3M Brand (or equivalent) Electrical Moisture Sealant Tape tightly to I/P harness for approximately 200mm (8 in.) starting at a point 150mm (6 in.) from bulkhead connector and continuing toward the cluster connector breakout (i.e. cover I/P harness in area of the hood release cable bracket and clutch bracket).

NOTICE: Be sure to apply sealant tape only to clean/dry surfaces.

4. Apply sealant tape to hood release cable bracket to cover all sharp edges. Press tape tightly against bracket for good adhesion.

5. Reposition harness as far away from hood release cable bracket as possible and reinstall A/C duct, knee bolster pad and lower trim pad assembly.

6. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Custoiner:

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in certain 1990 Chevrolet Corvette ZR1 model vehicles. The fuel feed and return line connectors of these vehicles were built with the incorrect line end flare configuration. If these lines are left uncorrected, the line ends could crack causinig a fuel leak which may result in an engine compartment fire.

Additionally, a non-safety recall will be performed on your vehicle while it is in for fuel line corrections. Some 1990 Chevrolet Corvette ZR1s may experience instrument panel wires rubbing on the hood release cable bracket causing wire abrasion. If this condition continues to exist, the instrument panel wiring may wear through and ground itself on the hood release cable bracket, possibly casusing a short in the vehicle's electrical system and an inoperable vehicle engine.

To prevent the possibility of a fuel leak or electrical abrasion condition occurring, new fuel lines with the correct end flare configuration will be installed on the involved vehicles. Also, protective electrical tape will be applied to the instrument panel wiring and hood release cable bracket, thus protecting the wires from abrasion. Additionally, instrument panel wiring which shows signs of abrasion will be repaired.

These services will be performed for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnrl in completing the necessary correction to your vehicle in the shortest possible time.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777, or if you live in Quebec, 1-800-263-7854.

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.