CAMPAIGN:A/C EVAPORATOR MAY IGNITE-PLASTIC PLUG REMOVAL
Models: 1984 GMC G15-25-35 Light Duty G-Van Trucks with Front and Rear A/C System (RPO C69)
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 adequatley repair within 60 days after tender of a vehicle is prima facie evidence of failure to repair within a reasonalbe 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 a service date with each owner and to repair his or her vehicle as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owner is being instructed to contact the nearest GMC Zone Office if their dealer does not remedy the condition within five days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed 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 1984 GMC G Vans equipped with a front and rear air conditioning system (RPO C69). Under certain conditions an engine compartment fire could occur if a plastic plug on top of the front air conditioner (A/C) evaporator blower housing was not removed during assembly. This could cause fire damage including burn injuries to passengers remaining in the vehicle.
A vehicle inspection of the A/C evaporator inlet case will be necessary to determine the service procedure and replacement parts required to prevent this from occurring.
VEHICLES INVOLVED
Involved are certain 1984 G15, G25 and G35 Light Duty G Van Model Trucks equipped with front and rear A/C systems (RPO C69). Vehicles involved were built within the following VIN breakpoints.
Plant From Through ------ ----- -------
Lordstown E7513827 E7516258 Scarborough E4514765 E4517475
The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are furnished to all involved dealers with the campaign 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 modification according to instructions contained in this bulletin.
If no owner's name and address were available to GMC Truck at the time of campaign initiation, the dealer will determine the owner's name and address from the dealership sales records. Please provide this information directly on the second copy of the listing next to the applicable VIN, so that our records may be updated and the appropriate notification mailed to the owner. This second copy should then be submitted to the address listed below in the previously supplied yellow campaign envelopes.
GMC Truck General Motors Corporation 101 Union Street Plymouth, Michigan 48170
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by GMC Truck (see copy of Owner letter included with this bulletin). A listing of owner names and addresses has been furnished to the involved dealers to enable dealers to follow up with owners involved in this campaign. This listing 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 this campaign.
SERVICE PROCEDURE
Inspect the A/C evaporator inlet case, located on the passenger side of the engine compartment near the hood, for any indication of melting or burning in the area of the rear A/C system blower speed control resistor (See Figure No. 1).
If there is no damage to the case, follow procedure A to replace resistor and remove any knockout plug pieces from case.
If there is damage to the case, follow procedure B(gasoline engine equipped) or procedure C (Diesel engine equipped), depending on the vehicle, to replace the resistor and A/C evaporator inlet case.
PROCEDURE A - GASOLINE OR DIESEL ENGINE EQUIPPED TRUCKS WITH NO DAMAGE TO A/C EVAPORATOR INLET CASE
1. With ignition key in the "off" position, disconnect negative battery cable.
2. Disconnect the three wire connector from the rear A/C system blower speed control resistor. (See Figure No. 1).
3. Remove the two resistor retaining screws from the A/C evaporator inlet case.
4. Remove the resistor from the case and discard.
5. Remove any pieces of the rear A/C system blower speed control resistor knockout plug from the opening in the case (see Figure No.2). Should a piece of the knockout plug fall into the bottom of the case, it is not necessary to remove it.
6. Install a new resistor, P/N 15591188, in the case. Torque the two resistor retaining screws to 1.2-1.6 NM (11-14 in. lbs.)
7. Attach the three wire connector to the resistor.
PROCEDURE B - GASOLINE ENGINE EQUIPPED TRUCKS WITH DAMAGE TO A/C EVAPORATOR INLET CASE
1. With ignition key in "off" position, disconnect the negative battery cable.
2. Remove auxiliary radiator overflow reservoir.
3. Discharge the air conditioning system. Refer to the 1984 Light Duty Truck Service Manual (X-8432) for instructions.
CAUTION:
to help avoid personal injury always wear goggles and wrap a clean cloth around fittings, valves and connections when doing work that involves opening the refrigerant system. Always work in awell ventilated area and do not weld or steam clean near any of the air conditioning components.
If refrigerant should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical attention.
4. Disconnect all electrical connections to the A/C evaporator case assembly.
5. Remove right front marker lamp.
6. Remove accumulator inlet and outlet lines and accumulator tank from vehicle.
7. Remove heater hose bracket.
8. Disconnect the plastic water line from the water valve.
9. Remove fasteners securing A/C evaporator case assembly and mounting hardware (three nuts and one screw). Remove case assembly from vehicle.
10. Remove evaporator core retaining screws and separate evaporator and blower inlet case sections.
11. Remove evaporator core, blower motor and cage assembly, relay, and resistors from case.
12. Install former front A/C system blower speed control resistor in new case. P/N 3054954, and torque retaining screws to 1.2-1.6 Nm (11-14 in. lbs.) This will provide increased rigidity to prevent cracking the new case when removing knockout plug in Step 13).
13. Carefully punch the rear A/C system blower speed control resistor knockout plug out of the new case. All pieces of this plug must be removed from the opening (See Figure No.2)
14. Install new rear A/C system blower speed control resistor. P/N 15591188, in the new case. torque the two resistor retaining screws to 1.2-1.6 Nm (11-14 in.lb.s) Discard old resistor.
15. Reinstall the evaporator core, blower motor & cage assembly, and relay on the new case.
16. Assemble A/C evaporator case assembly halves using rope sealant, P/N 3008851 or equivalent, applied to the sealing surfaces of new case.
17. Reinstall the A/C evaporator case assembly on the vehicle following the procedure in reverse. Reseal the case flange to the dash panel using rope sealant, P/N 3008851 or equivalent.
18. Evacuate and recharge the A/C system. Refer to the 1984 Light Duty Truck Service Manual (X-8432) for instructions.
PROCEDURE C - DIESEL ENGINE EQUIPPED TRUCKS WITH DAMAGE TO A/C EVAPORATOR INLET CASE
1. With ignition key in "off" position, disconnect the negative battery cable.
2. Discharge the air conditioning system. Refer to the 1984 Light Duty Truck Service Manual (X-8432) for instructions.
CAUTION:
To help avoid personal injury always wear goggles and wrap a clean cloth around fittings, valves and connections when doing work that involves opening the refrigerant system. Always work in a wll ventilated area and do not weld or steam clean near any of the air conditioning components.
If refrigerant should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical attention.
3. Remove auxiliary radiator overflow reservoir.
4. Remove right front marker lamp.
5. Remove blower motor insulation.
6. Disconnect all electrical connections to the A/C evapoarator case assembly and remove relay.
7. Disconnect accumulator inlet and outlet lines and move accumulator tank out of the way.
Note: When removing A/C components, make sure that the component is capped to prevent contamination.
8. Remove the two resistors from the housing.
9. Remove the evaporator core insulation.
10. Remove fasteners securing A/C evaporator case assembly and mounting hardware (3 nuts and 2 screws). Remove case assembly from vehicle.
11. Remove evaporator core retaining screws and separate evaporator and blower inlet case sections.
12. Remove evaporator core, blower motor and cage assembly from housing.
13. Install former front A/C system blower speed control resistor, in new case, P/N 3054954, and torque retaining screws to 1.2-1.6 Nm (11-14 in. lbs.) This will provide increased rigidity to prevent cracking the new case when removing the knockout plug in Step 14.
14. Carefully punch the rear A/C system blower speed control resistor knockout plug out of the new case. All pieces of this plug must be removed from the opening. (See Figure No. 2).
15. Install new rear A/C system blower speed control resistor, P/N 15591188, in the case. Torque the two retaining screws to 1.2-1.6 Nm (11-14 in lbs.) Discard old resistor.
16. Reinstall the evaporator core, blower motor and cage assembly, and relay on the new case.
17. Assemble A/C evaporator case assembly halves using rope sealant, P/N 3008851 or equivalent, applied to the sealing surfaces of new case.
18. Reinstall the A/C evaporator case assembly on the vehicle following the procedure in reverse. Reseal the housing to the dash panel using rope sealant, P/N 3008851 or equivalent.
19. Evacuate and recharge the A/C system. Refer to the 1984 Light Duty Truck Service Manual (X-8432) for instructions.
PARTS INFORMATION
Parts are to be obtained from the Warehousing and Distribution Division of General Motors (WDDGM). To ensure that these parts will be obtained as soon as possible, they should be ordered from WDDGM on a C.I.O. order with no special instruction code, but order on an advise code (2).
All trucks involved in the campaign will require the following part:
Quantity Part Number Per Vehicle Description ----------- ----------- ------------
15591188 1 Resistor
In addition, trucks requiring A/C evaporator inlet case replacement will need the following parts:
Part Number Quantity Per Vehicle Description ----------- -------------------- ------------
3054954 1 Case, Inlet Evaporator 3008851 A/R Rope Sealant
WARRANTY INFORMATION
Dealers should submit an accurately filled out Warranty Repair Order on each vehicle completed under this campaign.
Labor Operation **Net *Time Trouble Number Description Amount Allowance Code ------ ----------- ------ --------- ----
V2310 Inspect A/C evaporator 0.2 hour 96 inlet case, remove any resistor knockout plug pices and install new resistor.
V2311 Inspect and replace $1217 A/C evaporator inlet case. Includes installing new resistor
Gasoline Engine 1.9 hour 96 Diesel Engine 2.1 hour 96
*For dealer to receive Administration Time Allowance associated with this campaign add 0.1 hour to the Labor Operation Time Allowance.
**This amount, credit for R-12 refrigerant used, is to be entered in the Net Item Amount on the Warranty Claim.
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 (5) 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
Procedures covering this campaign are outlined in Section V of your dealership's "GMC Truck Claim Processing Manual" issued April, 1983.
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.
