CAMPAIGN: BRAKE S/LAMP SWITCH INSTALLATION & ADJUSTMENT

Subject: PRODUCT SAFETY CAMPAIGN 90C30 BRAKE STOPLAMP SWITCH

Model and Year: 1990 CHEVROLET LUMINA

To: All Chevrolet Dealers

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 repair within sixty (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.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1990 Chevrolet Lumina model vehicles. These vehicles may have a faulty brake stoplamp switch, which could result in the stoplamps not illuminating on application of the brakes. If this should occur in situations where a driver in a trailing vehicle is otherwise unable to recognize a braking action in sufficient time to respond appropriately, a vehicle crash could occur without prior warning. In some cases, failure of the stoplamp switch can result in the stoplamps staying on at all times.

In addition, in vehicles equipped with cruise control, a faulty stoplamp switch can result in resumption of the cruise control function upon release of the brake pedal. If this occurs, the cruise control feature can be disengaged by moving the cruise control switch to the "OFF" position, or by reapplying the brake. once the vehicle speed drops below 12-14 MPH, the cruise feature will be automatically disengaged.

To prevent these conditions from occurring, an improved stoplamp switch will be installed on all involved vehicles.

VEHICLES INVOLVED

Involved are certain 1990 Chevrolet Lumina model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH

1990 W-Car Oshawa #1 "9" L9100203 L9221197

1990 W-Car Oshawa #2 "1" L1100001 L1176453

1990 W-Car Oshawa #2 "1" L1400049 L1400248

VEHICLES WHICH CHEVROLET WARRANTY RECORDS INDICATE HAVE BEEN PREVIOUSLY REPAIRED WITH STOPLAMP SWITCH P/N 10180504, AND WHICH HAD A CLAIM SUBMITTED, PROCESSED AND PAID BY THE CLOSE OF BUSINESS FRIDAY, OCTOBER 12, 1990, HAVE BEEN REMOVED FROM THIS CAMPAIGN.

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 ---------- ------------------ --------- 10180504 Stoplamp Switch Assembly 1

GMSPO will preship each dealer (except COD dealers) five (5) stoplamp switch assemblies. These parts will be billed on the dealer parts account.

SERVICE PROCEDURE

NOTICE: ALL DEALERS ARE BEING SENT AN INSTRUCTIONAL VIDEO TAPE ON THE STOPLAMP SWITCH SETTING PROCEDURE. PLEASE BE SURE TO VIEW THIS VIDEO TAPE BEFORE PERFORMING THE PROCEDURE BELOW.

STOPLAMP SWITCH REMOVAL AND INSTALLATION

1. Remove air cleaner assembly and disconnect negative battery cable.

2. Remove left side sound insulator panel and slide steering shaft protective sleeve towards the cowl.

3. Disconnect air distribution tube and pull down.

4. Remove retainer clip holding stoplamp switch to steering column bracket.

5. Disconnect switch arm from pedal by pushing arm over and off brake pedal pin. Release switch by pulling down and releasing top snap clip.

6. Disconnect connector position assurance (CPA) locking pins from four wire and two wire electrical connectors. (Two wire connector not present on vehicles without cruise control feature.)

7. Disconnect four wire and two wire connectors.

8. Remove brake stoplamp switch assembly.

9. If vehicle is equipped with cruise control, connect two wire connector and CPA locking pin.

10. Install new switch assembly by pushing switch up until seated into top snap clip. Do not attach switch arm to pin on brake pedal at this time.

NOTICE: Make sure the brake switch is not adjusted (metal clip on the actuator is not engaged with the serrations on the bottom of the carrier) as shown in figure 2, page 7.

11. Install retainer clip which holds switch to steering column bracket.

12. Push brake pedal down to floor pan and install switch arm over and onto brake pedal pin.

13. Pull brake pedal all the way rearward and listen for switch to ratchet to set position. At least three he ratchet must be heard.

14. Connect four wire connector and CPA locking pin.

15. Position steering shaft protective sleeve.

16. Reconnect negative battery cable.

17. Inspect stoplamp switch operation. If stoplamps do not operate properly, refer to the "STOPLAMP SWITCH ADJUSTMENT" section of this bulletin. If stoplamps do operate properly, continue through step 23.

18. For vehicles equipped with cruise control, check setting of cruise control vacuum dump switch. With brake pedal at rest, make sure the plunger is fully seated into the barrel. If it is not fully seated, push the dump switch forward until the plunger is inside the barrel and then pull rearward on brake pedal to properly set the switch. If the plunger is already fully seated into the barrel, the dump switch is already properly set and no further adjustment is required.

19. Reconnect air distribution tube.

20. Reinstall left side sound insulator panel.

21. Reinstall air cleaner assembly.

22. Vehicles equipped with 3. 1L engines must have the following procedure performed to "relearn" the idle. This function was lost from the ECM's memory due to the loss of battery power.

a. Place air conditioning controls in "OFF" position.

b. Firmly apply parking brake and block drive wheels. Start engine and shift transaxle into "DRIVE" for automatics or "NEUTRAL" for manuals.

c. Allow engine to run a maximum of 10 minutes or until the engine cooling fan has cycled once, whichever occurs first.

d. Shift transaxle to "PARK" for automatics or "NEUTRAL" for manuals, then turn the ignition key to the "OFF" position for at least 5 seconds.

e. Repeat step (b).

f. Allow engine to run for at least 5 minutes.

23. Install Campaign Identification Label.

STOPLAMP SWITCH ADJUSTMENT

(Figure 1 on page 7 may be helpful in performing this procedure.)

1. Depress brake pedal as far as possible and hold.

2. Using a stiff wire with a hooked end (see figure on page 6), gently pull switch set lever forward (toward front of vehicle), and listen for an audible click indicating release of automatic adjustor.

NOTICE: If no click is heard, release brake pedal and repeat above procedure.

3. After release of automatic adjuster, pull brake pedal all the way rearward. Listen for switch to ratchet into set position (setting the stoplamp switch). At least three (3) clicks of the ratchet must be heard.

4. Inspect operation of stoplamps. Stoplamps should operate at maximum brake pedal travel of 25mm (1 inch) and throughout the remainder of its travel. If stoplamps do not operate properly, repeat switch adjustment procedure one more time. If switch still fails to operate properly, refer to the "STOPLAMP SWITCH ADJUSTMENT CHECK" chart on page 8.

If stoplamps do operate properly, return to step 18 of the "STOPLAMP SWITCH REMOVAL AND INSTALLATION" procedure above.

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 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 ---------------- -- -------- ----- ----- ----- --- ---

Install And Adjust Stoplamp Switch - 1 10180504 ** SK-00 V6370 0.7 0.1 Veh. W/ 2.5L Engine

Instatl And Adjust Stoplamp Switch - 1 10180504 ** SK-00 V6371 0.8 0.1 Veh. W/ 3.lL Engine

*** (Prior Repair) Review Repair Order -- -- -- -- ** - 10180504 Switch V6372 0.2 0.1 Already Installed

*** (Prior Repair) Reimburse Owner For -- -- -- -- ** T1690 0.0 0.0 Prior switch Repair

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

*** See "Reimbursement" section below for repair order review details required to complete this campaign.

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

CUSTOMERS WITH REIMBURSEMENT CLAIMS SHOULD HAVE THEIR REPAIR ORDERS REVIEWED TO DETERMINE IF AN IMPROVED DESIGN STOPLAMP SWITCH (P/N 10180504) WAS INSTALLED AT THE TIME OF REPAIR.

- IF THE PART NUMBER ON THE REPAIR ORDER I-S P/N 10180504; NO FURTHER ACTION IS REQUIRED. CLAIM V6372 AND REIMBURSE CUSTOMER UNDER T1690.

- IF THE PART NUMBER ON THE REPAIR ORDER IS NOT P/N 10180504, AN IMPROVED DESIGN STOPLAMP SWITCH (P/N 10180504) MUST STILL BE INSTALLED. PERFORM THE CAMPAIGN PROCEDURE OUTLINED IN THIS BULLETIN; CLAIM V6370 OR V6371 FOR THE REPLACEMENT AND REIMBURSE THE CUSTOMER FOR THE PRIOR REPAIR UNDER T1690.

Customer requests for reimbursement of previous repairs to correct a stoplamp switch 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, a description of the repair, the date of the repair, and the person or entity performing the repair.

REQUEST FOR REIMBURSEMENT INSTRUCTIONS PRODUCT SAFETY CAMPAIGN 90C30 (BRAKE STOPLAMP SWITCH - 1990 CHEVROLET LUMINA)

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 "O".)

5 CC/FC Code is preprinted on form.

6 LABOR OPEN Labor Operation as referenced in bulletin.

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

9 AUTH CODE If the amount of reimbursement approved is $100 or less, no authorization is needed. If the amount exceeds $100, 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 $100.)

11 APPROVED Dealer Service Manager to determine based on reimbursement policy of this bulletin. (Maximum amount is $100.)

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'sinvoices/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.

Dear Chevrolet Lumina Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR THIS RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1990 Chevrolet Lumina model vehicles. These vehicles may have a faulty brake stoplamp switch, which could result in the stoplamps not illuminating on application of the brakes. If this should occur in situations where a driver in a trailing vehicle is otherwise unable to recognize a braking action in sufficient time to respond appropriately, a vehicle crash could occur without prior warning. In some cases, failure of the stoplamp switch can result in the stoplamps staying on at all times.

In addition, in vehicles equipped with cruise control, a faulty stoplamp switch can result in resumption of the cruise control function upon release of the brake pedal. If this occurs, the cruise control feature can be disengaged by moving the cruise control switch to the "OFF" position, or by reapplying the brake. Once the vehicle speed drops below 12-14 MPH, the cruise feature will be automatically disengaged.

WHAT WE WILL DO

To prevent these conditions from occurring, an improved design stoplamp switch will be installed on your vehicle. This service will be performed 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. The labor time necessary to perform this service correction is approximately 3/4 of an hour. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

If you have already experienced this condition and 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 documentation which reasonably confirms the amount of unreimbursed repair expense, the date of repair and the person or entity performing the repair.

When you make your reimbursement request, your repair order will be reviewed to assure that an improved design stoplamp switch was installed. If another switch was used for the repair, it will need to be replaced and a service date to perform this campaign should be scheduled. If the improved design part was installed, your vehicle already has the required part and no further action is necessary. In either case, a claim for reimbursement of the prior repair may be filed.

Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffiuc Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123).

The enclosed owner 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 have sold or traded you 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 safety and 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.