CAMPAIGN: COOLANT LEAK AT RADIATOR SURGE TANK OUTLET. Chevrolet Corvette 1992

NOTE: THIS IS WITH FURTHER REFERENCE TO THE STOP DELIVERY DCS ADMIN 01-307 DATED 9-20-91. AFTER PERFORMING THE INSTRUCTIONS CONTAINED IN THE SERVICE PROCEDURE SECTION BELOW, INVOLVED VEHICLES ARE RELEASED FROM THE STOP DELIVERY.

GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1992 CORVETTES WITH LT1 (STANDARD) ENGINES MAY HAVE BEEN SHIPPED WITH SUSPECT RADIATOR SURGE TANK OUTLET HOSES WHICH COULD RUPTURE RESULTING IN LOSS OF ENGINE COOLANT.

TO CORRECT THIS CONDITION, DEALERS ARE TO INSTALL A NEW RADIATOR SURGE TANK OUTLET HOSE.

VEHICLES INVOLVED

INVOLVED ARE ALL CHEVROLET CORVETTE MODEL VEHICLES UP TO VIN N5101804 AND WHICH DO NOT HAVE A YELLOW PAINT MARK AT THE ENGINE END OF THE RADIATOR SURGE TANK OUTLET HOSE.

IF ANY OF THESE VEHICLES HAVE BEEN SOLD PRIOR TO PERFORMING THE REPAIR PROCEDURES CONTAINED IN THIS BULLETIN, THE OWNERS ARE TO BE CONTACTED BY THE SELLING DEALER AND ARRANGEMENTS MADE TO PERFORM THIS REPAIR.

OWNER NOTIFICATION

THERE WILL BE NO OWNER LETTER SENT OUT WITH THIS CAMPAIGN. DUE TO THE STOP SALE ISSUED PRIOR TO VEHICLE SALE, IT IS ANTICIPATED THAT VEHICLES ARE STILL IN DEALER NEW VEHICLE INVENTORY AND WILL BE REPAIRED PRIOR TO RETAIL SALE. IF A VEHICLE HAS BEEN RETAILED, IN ORDER TO MAINTAIN CUSTOMER SATISFACTION, CONTACT THE OWNER IMMEDIATELY AND ARRANGE TO CORRECT THIS CONDITION ON THEIR VEHICLE.

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). DUE TO ANTICIPATED LOW PARTS QUANTITIES, ONLY DEALERS WHICH HAVE INVOLVED STOCK UNITS SHOULD PLACE PARTS ORDERS ONCE PARTS ARE AVAILABLE.

PART NUMBER DESCRIPTION QTY/VEHICLE

10135697 RADIATOR SURGE TANK OUTLET HOSE 1

SERVICE PROCEDURE

1. RAISE VEHICLE ON HOIST HIGH ENOUGH TO ACCESS RADIATOR DRAIN PLUG.

NOTICE: TO AVOID BEING BURNED, DO NOT REMOVE SURGE TANK CAP FROM RADIATOR SURGE TANK WHILE ENGINE IS AT NORMAL OPERATING TEMPERATURE. THE COOLING SYSTEM WILL RELEASE SCALDING FLUID AND STEAM UNDER PRESSURE IF CAP IS REMOVED WHILE ENGINE AND RADIATOR ARE STILL HOT.

2. REMOVE PRESSURE CAP FORM TANK WHEN ENGINE IS COOL BY:

- SLOWLY ROTATING COUNTER CLOCKWISE TO DETENT (DO NOT PRESS DOWN WHILE ROTATING).

- WAIT UNTIL ANY LEFT OVER PRESSURE (INDICATED BY A HISSING SOUND) IS RELEASED.

- AFTER ALL HISSING STOPS, PRESS DOWN ON CAP WHILE CONTINUING TO ROTATE COUNTER-CLOCKWISE.

3. WITH A CLEAN DRAIN PAN IN PLACE, OPEN THE RADIATOR DRAIN VALVE.

4. ONCE ENOUGH FLUID HAS DRAINED OUT OF SURGE TANK, REMOVE SURGE TANK OUTLET HOSE END FROM TANK WHILE HOLDING HOSE CLAMP OPEN WITH A PAIR OF PLIERS.

5. REMOVE ENGINE END OF HOSE (FROM BELOW THERMOSTAT HOUSING) IN SAME MANNER AS TANK END.

6. CLOSE RADIATOR DRAIN VALVE.

7. TRANSFER HOSE CLAMPS TO NEW RADIATOR SURGE TANK OUTLET HOSE AND INSTALL NEW HOSE BETWEEN ENGINE AND SURGE TANK.

8. POUR DRAINED COOLANT INTO SURGE TANK UNTIL TANK IS FILLED.

9. OPEN BLEED VALVE AT THERMOSTAT HOUSING NECK AND ALLOW COOLANT IN SURGE TANK TO SETTLE (DO NOT OPEN BLEED AT THROTTLE BODY).

10. CLOSE BLEED VALVE AT THERMOSTAT HOUSING.

11. REFILL SURGE TANK TO TOP WITH COOLANT, START ENGINE AND RUN FOR 5 MINUTES (OR UNTIL RADIATOR INLET HOSE IS HOT).

12. TOP OFF RADIATOR SURGE TANK WITH COOLANT AND INSTALL SURGE TANK CAP.

13. FILL COOLANT RECOVERY RESERVOIR TO "HOT" LINE WITH COOLANT.

NOTICE: "COOLANT" IS A 50/50 MIX OF WATER AND ETHYLENE GLYCOL.

14. LOWER VEHICLE.

15. INSTALL CAMPAIGN IDENTIFICATION LABEL.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS PROVIDED IN THIS PRODUCT CAMPAIGN 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 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:

REPAIR PART LABOR LAB OTH PERFORMED PC ALLOW CC/FC OP HRS HRS

INSTALL NEW HOSE 1 ** SK-00 V7030 0.7 0.1

INSPECT FOR YELLOW - -- SK-00 V7031 0.2 0.1 PAINT MARK ON HOSE

* CAMPAIGN ADMINISTRATIVE ALLOWANCE.

** THE "PART 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 TIME AND MATERIAL ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED.

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

PLEASE COMMUNICATE THIS INFORMATION TO DEALERSHIP SALES AND SERVICE MANAGEMENT UPON RECEIPT.

I. L. CLAY, MANAGER TECHNICAL SERVICE DEPARTMENT

CHEVROLET 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 EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS, AND KNOW-HOW TO DO A JOB PROPERLY AND SAFETY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE HAS THAT CONDITION. SEE YOUR CHEVROLET DEALER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THAT INFORMATION.