CAMPAIGN:A/C CONDENSER (INSPECT/REPLACE)

AIR CONDITIONER CONDENSER 1988 Optima with Air Conditioning

TO: ALL GM & PASSPORT DEALERS:

General Motors of Canada has determined that some 1988 Optima model vehicles equipped with air conditioning (A/C) may exhibit vibration of the A/C compressor-to-condenser refrigerant hose. This condition, over time, can result in fatigue fracture of the condenser tubes at the inlet to the condenser and header joints. This condition could then lead to loss of refrigerant from the A/C system and subsequent loss of cooling performance.

To prevent the possibility of this condition occurring, a bracket (support) assembly will be installed on all involved vehicles to eliminate refrigerant hose vibration. Also, the condenser will be inspected for leaks and, if required, replaced.

VEHICLES INVOLVED:

Involved are certain 1988 Pontiac LeMans Model vehicles equipped with A/C and produced within the following VIN breakpoints:

Plant From Through ----- ---- -------

Pupyong (Korea) SOP EOP

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.

PARTS INFORMATION:

Parts required should be ordered through regular channels, as follows:

Quantity/ Part Number Description Vehicle - ----------- ----------- ----------

90245328 Bracket Asm. - A/C Discharge Line 1

The following parts are necessary only when condenser replacement is required:

96082210 Condenser - A/C 1

9288675 "O"-Ring - Refrig. Lqd. Pipe 1 (10.8mm I.D.)

9288674 "O"-Ring - Refrig. Lqd. Pipe 1 (7.65mm I.D.)

NPN R-14 Refrigerant 2.2 lbs.

It is estimated that only 3.5% may require condenser replacement. Order parts accordingly based on attached involved vehicle listings.

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 `Quick Check' A/C System .6 And Install Bracket

3A `Quick Check' A/C System, 2.3 And Replace Condenser And Install Bracket

Time allowance includes 0.1 hour for Dealer administrative detail associated with this campaign. Parts credit will be based on Dealer net plus 30% to cover parts handling. An amount of $6.75 will be included to cover the cost . of 2.2 lbs. of R-14 refrigerant used when condenser replacement is necessary.

SERVICE PROCEDURE:

1. Perform "Insufficient Cooling 'Quick Check' Procedure" described in Service Manual, Section 1B. If the procedure indicates a low charge condition, leak test (see Service Manual) condenser adjacent to inlet pipe using an electronic leak detector.

2. If Step 1 indicates a condenser leak is present, replace condenser per Service Manual instructions. Charge system and continue with steps 3 through 10 below.

If an A/C system leak is present other than condenser leakage as described in this bulletin, it should be handled separately under the A/C warranty applicable to the vehicle. Then charge system and continue with steps 3 through 10 below.

Installation of Bracket Assembly

3. Remove front engine mount nut and washer at right hand (passenger) side of engine compartment (Figure 1) using a 17mm wrench.

4. Remove two (2) hex head bolts and inlet pipe clamp from new bracket assembly, loosen two (2) isolator retaining nuts (Figure 2).

5. Install new bracket to right hand front engine mount stud with front arm of bracket passing underneath condenser inlet pipe as shown in Figure 3. Reinstall engine mount washer and nut, finger tight only, since adjustment of bracket position and angle may be required.

6. Install inlet pipe clamp to bracket using two (2) hex head bolts (10mm wrench). Cut-out in inlet pipe clamp must face towards rear of vehicle. Locate clamp on straight section of pipe. Clamp must not contact pipe connecting nut or bend section of pipe, see Figure 4. Access to hex head bolts can be gained using a wrench extension inserted between air cleaner intake and top radiator hose as shown in Figure 5. Tighten bolts to 3 N.m (2.2 lbs. ft.).

7. Tighten two (2) isolator retaining nuts to 4.5 N.m (3.3 lbs. ft.) using a 10mm wrench.

8. Loosen right hand front engine mount nut to allow bracket to be positioned in a 'neutral' (no distorting force on isolator) position.

9. Tighten right hand front engine mount nut to 40 N.m (29.5 lbs. ft.).

10. 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.

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.