CAMPAIGN: CALIFORNIA EMISSIONS TURBO ENGS. DO NOT COMPLY

GENERAL MOTORS HAS DETERMINED THAT SOME 1980 MONTE CARLOS EQUIPPED WITH CALIFORNIA TURBOCHARGED ENGINES DO NOT COMPLY WITH THE STATE OF CALIFORNIA EMISSION STANDARDS.

TO CORRECT THIS CONDITION ON THESE VEHICLES AND TO ENSURE THAT THEY MEET APPLICABLE CALIFORNIA EMISSION REQUIREMENTS, CHEVROLET DEALERS ARE TO INSTALL A NEW TURBOCHARGER EXHAUST OUTLET PIPE, A NEW PROM IN THE ELECTRONIC CONTROL MODULE AND A NEW A.I.R. MANAGEMENT VALVE ADAPTER; PLUS, PERFORM ALL THE CHECKS AND ADJUSTMENTS LISTED IN THE TECHNICAL PROCEDURE OF THIS BULLETIN.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1980 CHEVROLET MONTE CARLO MODELS EQUIPPED WITH RPO (YF5) CALIFORNIA EMISSION REQUIREMENT AND RPO (LC8) TURBOCHARGE ENGINE WITHIN THE FOLLOWING VEHICLE BREAKPOINTS:

PLANT FROM THROUGH

ARLINGTON AR400001 AR432339

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 FOR THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN.

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.

SERVICE PROCEDURE

A. UNDER HOOD INSPECTION (CORRECT ITEMS AS REQUIRED)

1. CHECK ALL ELECTRICAL CONNECTIONS ON ENGINE AND EMISSION CONTROLS, PAYING SPECIAL ATTENTION TO SPARK PLUG WIRES.

2. CHECK ALL VACUUM HOSE ROUTINGS AND CONNECTIONS PER THE VEHICLE EMISSION CONTROL INFORMATION LABEL.

B. CARBURETOR REAR VACUUM BREAK ADJUSTMENT

1. ADJUST CARBURETOR REAR VACUUM BREAK SETTING TO 18 DEG. REFER TO FIGURE 1.

C. REPLACE A.I.R. MANAGEMENT VALVE ADAPTER

1. DISCONNECT ELECTRICAL CONNECTOR AND VACUUM HOSE ON SWITCHING VALVE. REFER TO FIGURE 2. 2. LOOSEN HOSE CLAMPS AND TWO (10MM) SCREWS SECURING SWITCHING VALVE TO BRACKET.

3. REMOVE ADAPTER AND INSTALL NEW ADAPTER PART #25507592.

4. REINSTALL SWITCHING VALVE, CONNECTING ALL HOSES AND ELECTRICAL CONNECTOR.

DO NOT TIGHTEN HOSE CLAMPS AT THIS TIME AS THIS WILL BE DONE DURING THE PERFORMANCE CHECK BELOW.

D. REPLACE TURBOCHARGER EXHAUST OUTLET PIPE

1. IF SO EQUIPPED, REMOVE THE FOUR (4) A/C COMPRESSOR BRACKET BOLTS INDICATED ON FIGURE 3. MOVE COMPRESSOR ASSEMBLY FORWARD AND ROTATE COUNTER CLOCKWISE AND POSITION ON FAN SHROUD. DO NOT DISCONNECT REFRIGERANT HOSES.

2. REMOVE TURBOCHARGER EXHAUST INLET PIPE. REFER TO FIGURE. 4.

3. DISCONNECT BOTH ENDS OF TURBO OUTLET PIPE AND REMOVE BY ROTATING OUTBOARD, THEN MOVING FORWARD UNDER REFRIGERANT HOSES TO REAR OF BATTERY CASE AND THEN UP AND OUT OF ENGINE COMPARTMENT.

4. INSTALL NEW TURBO OUTLET PIPE, PART NUMBER 25509533, REUSING SEAL BETWEEN PIPE AND TURBOCHARGER. REFER TO FIGURE 4.

5. REINSTALL INLET PIPE AND AIR CONDITION COMPRESSOR ATTACHING BOLTS.

6. ADJUST COMPRESSOR BELT TENSION. REFER TO PAGE 3B3-2 IN 1980 CHASSIS SERVICE MANUAL.

E. ECM PROM REPLACEMENT

1. REMOVE ECM COVER FROM RIGHT KICK PAD. REFER TO FIGURE 5.

2. TURN IGNITION SWITCH TO "ON" POSITION (ENGINE NOT RUNNING) AND GROUND ECM DIAGNOSTIC LEAD. RECORD ANY STORED ECM TROUBLE CODES. TURN IGNITION OFF.

3. REMOVE CALIBRATION PROM AND INSTALL NEW PROM #16017223 INCLUDED IN SERVICE PACKAGE 1224687. REFER TO FIGURES 6 AND 7.

4. PLACE NEW PROM CODE "ML" STICKER INCLUDED IN PROM SERVICE PACKAGE OVER OLD PROM CODE (BB OR BS) STICKER ON ECM.

5. IF ANY TROUBLE CODES WERE RECORDED IN STEP 2 ABOVE, CONDITION IS TO BE CORRECTED. REFER TO PAGES 6E1-7 THRU 6E1-47 OF THE 1980 CHEVROLET CHASSIS SERVICE MANUAL SUPPLEMENT ST-329-80D FOR TROUBLE CODE DIAGNOSIS CHARTS.

F. EGR VALVE CHECK

1. DISCONNECT ELECTRICAL CONNECTOR FROM COOLANT SENSOR LOCATED AT RIGHT FRONT SIDE OF INTAKE MANIFOLD. REFER TO FIGURE 8.

2. WITH TRANSMISSION IN "PARK" AND ENGINE RUNNING, WATCH FOR MOVEMENT OF THE EGR VALVE'S VACUUM DIAPHRAGM WHILE INCREASING ENGINE SPEED TO APPROXIMATELY 2,000 RPM. THE DIAPHRAGM SHOULD NOT MOVE.

3. IF EGR VALVE DIAPHRAGM MOVED IN STEP 2 ABOVE, THIS INDICATES THE EFE/EGR RELAY, PART NUMBER 25509793 IS DEFECTIVE AND SHOULD BE REPLACED. REFER TO FIGURE 9. (IF THE PROBLEM PERSISTS, SEE EGR/EFE CHECK, PAGE 6E1-9 OF THE 1980 CHEVROLET CHASSIS SERVICE MANUAL).

4. RECONNECT ELECTRICAL CONNECTOR AT COOLANT SENSOR.

5. RUN ENGINE UNTIL WARM. THEN WITH ENGINE WARM, TRANSMISSION IN "PARK" AND ENGINE RUNNING, WATCH FOR MOVEMENT OF THE EGR VALVE'S DIAPHRAGM WHILE INCREASING ENGINE SPEED TO APPROXIMATELY 2000 RPM. THE DIAPHRAGM SHOULD MOVE.

6. IF EGR VALVE'S DIAPHRAGM DID NOT MOVE IN STEP 5 ABOVE, REFER TO EGR/EFE CHECK ON PAGE 6E3 TO 6E-8 OF THE 1980 CHASSIS SERVICE MANUAL ST-329-80.

G. ENGINE TIMING AND IDLE CHECKS

1. CHECK AND ADJUST, AS REQUIRED, ENGINE TIMING AND IDLE SPEED PER THE VEHICLE EMISSION CONTROL LABEL.

H. C-4 DIAGNOSTIC AND SYSTEM PERFORMANCE CHECKS

NOTE: DIAGNOSTIC CHARTS ARE FOR THIS PROGRAM ONLY.

1. PERFORM C-4 DIAGNOSTIC CIRCUIT CHECK. REFER TO PROCEDURE SHOWN IN FIGURE 10.

2. PERFORM C-4 SYSTEM PERFORMANCE CHECK. REFER TO FIGURE 11. THE AIR MANAGEMENT CHECK WHICH IS PART OF SYSTEM PERFORMANCE IS ON FIGURE 13 OF THIS BULLETIN.

3. CORRECT ANY DISCREPANCIES FOUND ON ABOVE CHECKS. REFER TO PAGES 6E1-7 THRU 6E1-47 IN 1980 SERVICE MANUAL SUPPLEMENT ST-329-80D FOR APPLICABLE TROUBLE DIAGNOSIS CHART.

4. INSERT ECM IN COVER AND REINSTALL IN VEHICLE.

PARTS INFORMATION

DEALERS ARE REQUESTED TO ORDER ONE EACH OF THE FOLLOWING PARTS FOR EACH VEHICLE INVOLVED FROM THEIR LOCAL GENERAL MOTORS PARTS DIVISION.

PART NUMBER PART DESCRIPTION

25509533 TURBOCHARGER OUTLET PIPE

1224687 ELECTRONIC CONTROL MODULE (ECM) PROGRAMABLE REAR ONLY MEMORY (PROD) SERVICE PACKAGE

25507592 AIR INJECTION REACTOR (A.I.R.) MANAGEMENT VALVE ADAPTER

25509793 EARLY FUEL EVAPORATIVE CONTOL VALVE (EFE) EXHAUST GAS RECIRCULATION CONTROL VALVE (EGR) RELAY NOTE: TO INSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE, THEY SHOULD BE ORDERED FROM GMPD ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2). PARTS WILL BE AVAILABLE AFTER SEPTEMBER 8, 1980.

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW:

FAILURE FAILED LABOR LABOR OPERATION *OTHER HOURS CODE OPERATION HOURS ALLOWANCE ALLOWANCE

00 V0420 2.6 HOURS .1 HOURS

DESCRIPTION: REPLACE OUTLET PIPE, ECM PROM, AIR MANAGEMENT VALVE ADAPTER AND PERFORM ALL CHECKS AND ADJUSTMENTS IN "TECHNICAL PROCEDURE"

00 V0421 2.7 HOURS .1 HOURS

DESCRIPTION: INCLUDES ALL ITEMS IN OPERATION #V0420 PLUS REPLACE EFE/EGR RELAY.

*DEALERS WILL AUTOMATICALLY RECEIVE .1 HOURS DEALER ADMINISTRATIVE ALLOWANCE ASSOCIATED WITH THIS CAMPAIGN.

DEALERS WILL AUTOMATICALLY RECEIVE 30% OF DEALER NET FOR PARTS USED IN THIS CAMPAIGN BULLETIN. FAILED LABOR OPERATION V0420 ($24.86) V0421 ($25.32).

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 BE 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

THE APPROPRIATE CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURE MAY BE FOUND IN THE CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL, SECTION IV, PAGES 1 AND 2, DATED OCTOBER, 1979 IN YOUR DEALERSHIP.

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.