PRODUCT IMPROVEMENT 1980 PHOENIX CARBURETOR

GENERAL MOTORS HAS DETERMINED THAT A CARBURETOR LEAN FUEL MIXTURE MAY AFFECT ENGINE OPERATION ON CERTAIN EARLY PRODUCTION 1980 PHOENIX MODELS. WHEN THE VEHICLES ARE DRIVEN AT A CONSTANT SPEED IN THE 35 MPH RANTE, AND ENGINE SURGE CONDITION MAY BE EXPERIENCED. TO IMPROVE ENGINE OPERATION UNDER LIGHT THROTTLE CONDITIONS, DEALERS ARE TO REPLACE THE POWER PISTON AND SPRING ON AFFECTED VEHICLES, AND ADJUST ENGINE IDLE SPEED FOLLOWING THE SERVICE PROCEDURES IN THIS BULLETIN. VEHICLES INVOLVED INVOLVED ARE CERTAIN EARLY PRODUCTION 1980 PHOENIX MODELS ASSEMBLED AT GMAD TARRYTOWN. PLANT BEGINNING V.I.N. UP TO 1980 TARRYTOWN SOP 2Y375AT101831

VEHICLES INVOLVED IN THIS PRODUCT IMPROVEMENT CAMPAIGN WILL HAVE ONE OF THE FOLLOWING ENGINE CODES WA,WB,XA OR XB. SOME VEHICLES WITH V.I.N.'S WITHIN THE ABOVE LISTED RANGE OF NUMBERS WERE CORRECTED IN THE PLANT AND WILL NOT APPEAR ON THE PRINTOUT. DEALER CAMPAIGN RESPONSIBILITY DEALERS ARE TO PERFORM THIS PRODUCT IMPROVEMENT CAMPAIGN ON ALL AFFECTED VEHICLES IN NEW CAR STOCK PRIOR TO VEHICLE SALE. DEALER ACTION DEALERS ARE TO INSPECT AND, IF NECESSARY, INSTALL THE CARBURETOR POWER PISTON SPRING REPLACEMENT KIT AS DIRECTED IN THE SERVICE PROCEDURE IN THIS BULLETIN. IN ADDITION ON MANUAL TRANSMISSION VEHICLES, DEALERS ARE TO INSTALL A NEW TUNE UP LABEL AS DIRECTED IN THE SERVICE PROCEDURE. SERVICE PROCEDURES 1. OPEN HOOD AND OBSERVE ENGINE CODE LABEL ON TIMING COVER OR ENGINE CODE STAMPING ON PAD AT LEFT FRONT OF CYLINDER BLOCK BELOW CYLINDER HEAD (SEE FIGURE 0). VEHICLES WHICH REQUIRE MODIFICATIONS WILL HAVE THE FOLLOWING ENGINE CODES. WA 4-CYL 4-SPEED WITHOUT A/ WB 4-CYL 4 SPEED WITH A/C XA 4 CYL. AUTOMATIC WITHOUT A/C XB 4-CYL AUTOMATIC WITH A/C 2. IF THE ENGINE CODE IS OTHER THAN THOSE SHOWN ABOVE; NO MODIFICATION IS REQUIRED. PROCEED TO STEP 39. 3. IF THE ENGINE CODE IS ONE OF THE ABOVE, PROCEED TO STEP 4. 4. INSTALL PROTEVTIVE COVERS ON FENDERS. 5. REMOVE AIR CLEANER; INCLUDES TWO (2) NUTS ON AIR CLEANER COVER, ONE (1) BOLT ON INLET PIPE AND DISCONNECTING FRESH AIR INLET, PCV INLET PIPE AND THERMAC VACUUM HOSE. 6. DISCONNECT VACUUM HOSE AND IDLE SOLENOID WIRE FROM VACUUM BREAK ASSEMBLY. 7. REMOVE UPPER AND LOWER VACUUM BREAK BRACKET TO CARBURETOR SCREWS AND REMOVE VACUUM BREAK ASSEMBLY BY LIFTING AND ROTATING TO DISCONNECT LINKAGE (FIGURE 1.) 8. REMOVE CLIP FROM INTERMEDIATE CHOKE ROD AT CHOKE LEVER, DISCONNECT ROD AND REMOVE ROD BUSHING (FIG.2) NOTICE: DO NOT REUSE CHOKE ROD CLIP. A NEW CLIP AND BUSHING IS INCLUDED IN THE MODIFICATION PACKAGE. 9. REMOVE PUMP LEVER TO AIR HORN SCREW AND SPACER WASHER AND ROTATE LEVER TO DISCONNECT LINKAGE (FIG.3 AND 4). NOTICE: DO NOT REUSE THE SPACER WASHER. A NEW PUMP SCREW SPACER WASHER IS INCLUDED IN THE MODIFICATION PACKAGE. 10. IF THE VEHICLE IS EQUIPPED WITH AIR CONDITIONING (A/C), REMOVE THE HOT IDLE COMPENSATOR AND SEAL FROM THE AIR HORN AND DISCARD THE SEAL (FIG.5). 11. REMOVE THE TWO (2) VENT SCREEN SCREWS AND REMOVE THE SCREEN ASSEMBLY. 12. DISCONNECT BOWL VENT HOSE. 13. REMOVE THE REMAINING AIR HORN TO BOWL SCREWS AND STUDS AND REMOVE AIR HORN BY LIFTING AND ROTATING TO DISCONNECT FAST IDLE CAM LINKAGE. HOLDING THE CAM IN THE HIGH STEP POSITION WILL AID REMOVAL (FIB. 6). 14. REMOVE AND DISCARD AIR HORN TO BOWL GASKET. 15. REMOVE POWER PISTON AND METERING ROD ASSEMBLY BY PUSHING PISTON DOWN AND LETTING IT SNAP BACK AGAINST THE RETAINER (FIG. 7). NOTICE: IF THE RETAINER HAS NOT MOVED AFTER SEVERAL SNAPS, PLACE A SOFT BLOCK ACROSS THE BOWL TOP AND REMOVE THE PISTON WITH PLIERS USING THE BLOCK TO PROTECT THE GASKET SURFACE. EXERCISE CARE DURING REMOVAL SO THAT BOWL AND METERING ROD ARE NOT DAMAGED. 16. DISCONNECT THE METERING ROD FROM THE POWER PISTON ARM BY COMPRESSING THE SPRING AND SLIDING THE ROD FROM THE RETAINING GROOVE. DISCARD POWER PISTON (FIG. 8). NOTICE: PISTON AND/OR SPRING MAY POP OUT WITH SOME FORCE. USE CAUTION WHEN REMOVING. 17. REMOVE AND DISCARD POWER PISTON SPRING (STEEL:NO COLOR). 18.OBTAIN THE CARBURETOR MODIFICATION PACKAGE AND REASSEMBLE THE CARBURETOR AS FOLLOWS. CONTENTS OF PACKAGE ILLUSTRATED IN FIG. 9. 19. INSTALL THE NEW POWER PISTON SPRING IN PISTON BORE. 20. CONNECT THE METERING ROD TO THE NEW POWER PISTON AND INSTALL THE PISTON AND ROD ASSEMBLY IN THE BOWL. NOTICE: IT MAY BE NECESSARY TO LIGHTLY TAP THE POWER PISTON RETAINER WITH A FLAT OBJECT, FROM SIDE-TO-SIDE IN ORDER TO OBTAIN A FULL SEAT IN THE BORE. 21. PLACE THE NEW AIR HORN TO BOWL GASKET ON THE BOWL TAKING CARE TO WORK THE POWER PISTON ASSEMBLY THROUGH THE SLITS PROVIDED IN THE GASKET. 22.INSPECT FOR THE FOLLOWING:

A. FLOAT AND RETAINER ARE STILL IN PLACE. B. POWER PISTON AND METERING ROD WORK FREELY. C. PUMP SPRING IS IN THE BOTTOM OF THE PUMP BORE. D. PUMP PLUNGER IS N PLACE IN THE AIR HORN. 23. INSTALL AIR HORN ASSEMBLY BY RECONNECTING THE CHOKE LEVER TO FAST IDLE CAM ROD AND ROTATING THE AIR HORN TO THE UPRIGHT POSITION. HOLDING THE CAM IN THE HIGH STEP POSITION WILL AID IN CONNECTING THE LINKAGE. 24. INSTALL THE AIR HORN TO BOWL SCREWS AND STUDS, INCLUDING VENT SCREEN AND SCREWS, AND LIGHTLY TORQUE. NOTICE: THE PROVIDED METAL CARBURETOR IDENTIFICATION TAG, STAMPED "MOD.", SHOULD BE PLACED UNDER SCREW 6. NOTICE: THE SCREWS ARE NOT ALL THE SAME LENGTH. BE SURE TO INSTALL THE PROPER LENGTH SCREWS IN THE CORRECT LOCATIONS. (SEE ILLUSTRATIONS FOR PROPER LOCATION AND TORQUE SEQUENCE.) (FIG. 6 AND FIG. L0.) 25. IF THE VEHICLE IS EQUIPPED WITH A/C, INSTALL THE NEW SEAL AND PLACE THE HOT IDLE COMPENSATOR ON THE AIR HORN USING THE TWO (2) RETAINING SCREWS (FIG.5). 26. ATTACH THE PUMP ARM TO THE THROTTLE LINK AND INSTALL THE ARM TO AIR HORN SCREW THROUGH THE ARM USING THE NEW SPACER PROVIDED. HOLD THE PUMP SHAFT DOWN UNTIL THE SCREW IS SEATED (FIG. 4). 27. INSTALL A NEW SLEEVE ON THE CHOKE INTERMEDIATE ROD, ROTATE THE CHOKE ARM COUNTERCLOCKWISE TO THE UPWARD POSITION AND INSTALL THE FREE END OF THE ROD WITH THE SLEEVE INTO THE CHOKE LEVER. 28. INSTALL A NEW RETAINING CLIP ON THE INTERMEDIATE CHOKE ROD SO THAT THE OUTWARD BEND OF THE CLIP IS FACING THE END OF THE ROD. THE CLIP MUST HAVE A FULL CONTACT ON THE SHAFT AND MUST NOT BE TIGHTLY SEATED AGAINST THE SPACER (CLIP TO SPACER CLEARANCE SHOULD BE .8MM (.030"). 29. INSTALL VACUUM BREAK ASSEMBLY BY ROTATING TO CONNECT LINKAGE AND PLACING THE ASSEMBLY OVER THE LOCATING LUGS (FIG. 1). 30. INSTALL THE TWO (2) VACUUM BREAK TO CARBURETOR SCREWS. NOTICE: THE VACUUM BREAK TO AIR HORN SCREW (TOP SCREW) HAS A TAPERED HEAD FOR LOCATION AND MUST BE TIGHTENED FIRST. 31. CONNECT VACUUM HOSE TO VACUUM BREAK CONNECTOR AND ELECTRICAL CONNECTOR TO IDLE SPEED CONTROL. 32. INSTALL BOWL VENT HOSE. 33. CHECK LINKAGE AND THROTTLE FOR FREENESS AND PROPER OPERATION. 34. PLUG THE OPEN VACUUM FITTING FOR THE AIR CLEANER AND CONNECT AN ACCURATE TACHOMETER. 35. SET THE PARKING BRAKE, START THE ENGINE AND ALLOW IT TO WARM UP. 36. SET CURB AND FAST IDLE TO THE SPECIFICATIONS ON THE EMISSIONS LABEL. NOTICE: ON MANUAL TRANSMISSION VEHICLES, INSTALL THE NEW EMISSION LABEL PROVIDED AND ADJUST ENGINE SPEEDS TO THE REVISED SPECIFICATIONS. MANUAL TRANSMISSION VEHICLES WILL HAVE EITHER CODE FM OR FN LISTED NEXT TO THE VIN ON DEALER CAMPAIGN LISTS INDICATING REQUIRED NEW LABEL. CLEAN THE OLD LABEL WITH SOAPY WATER AND WIPE DRY. NEW LABEL NO.10009956, CODE FM, SHOULD BE APPLIED OVER OLD LABEL NO. 10009951, CODE FF, ON 4-CYLINDER 4-SPEED WITHOUT A/C. NEW LABEL NO. 10009957, CODE FN, SHOULD BE PLACED OVER OLD LABEL NO. 10009950, CODE FD, ON 4-CYLINDER 4-SPEED WITH A/C. 37. TURN ENGINE OFF, CONNECT COMPRESSOR ON A/C, REMOVE TACHOMETER AND PLUG FROM VACUUM FITTING. 38. INSTALL THE AIR CLEANER, REMOVE THE PROTECTIVE FENDER COVERS, AND CLOSE HOOD. 39. COMPLETE THE CAMPAIGN CARD AND MAIL IT TO PONTIAC. -REFER TO FIGURE 11 FOR 1980 PHOENIX SPECIFICATIONS- ENCLOSED WITH YOUR COPY OF THIS LETTER ARE THE FOLLOWING: A LIST OF THOSE VEHICLES INVOLVED WHICH OUR RECORDS INDICATE HAVE BEEN SHIPPED TO YOUR DEALERSHIP IS ATTACHED. ADVISE THE ZONE IF ANY OF THE VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. A SPECIAL PINK COLORED COMPUTER DATA CARD IS FURNISHED FOR EACH VEHICLE ON YOUR LIST FOR REPORTING COMPLETION. IF A VEHICLE HAS BEEN TRANSFERRED TO ANOTHER LOCATION, PLEASE FORWARD THE VEHICLE CARD AND DETAILS OF THE TRANSFER TO YOUR PONTIAC ZONE OFFICE. PARTS INFORMATION EACH DEALER WILL RECEIVE NO-CHARGE ONE CARBURETOR POWER PISTON SPRING REPLACEMENT KIT FOR EACH VEHICLE ON THEIR V.I.N. LIST. THIS KIT INCLUDES ONE (1) POWER PISTON, ONE (1) POWER PISTON SPRING, TWO (2) CLIPS, ONE (1) BUSHING, ONE (1) AIR HORN GASKET, ONE (1) WASHER, ONE (1) HOT IDLE COMPENSATOR VALVE GASKET, AND ONE (1) METAL CARBURETOR IDENTIFICATION TAG. ALSO, ENCLOSED WITH THE DEALER'S CAMPAIGN MATERIAL IS EITHER TUNE-UP LABEL NO. 10009956, CODE FM OR NO. 10009957, CODE FN TO BE USED ON MANUAL TRANSMISSION VEHICLES. DISPOSITION OF REPLACED PARTS ALL PARTS REMOVED FROM THE INVOLVED VEHICLES ARE TO BE RETAINED FOR DISPOSITION BY ZONE PERSONNEL. RECORDING COMPLETION CAMPAIGN COMPLETION WILL BE RECORDED FROM PROPERLY COMPLETED AND PAID WARRANTY CLAIMS AND DEALER COMPLETION OF SPECIAL PINK COLORED COMPUTER DATA CARDS. THE COMPUTER DATA CARDS FOR THE VEHICLES SHOWN ON YOUR LIST ARE INCLUDED WITH THIS BULLETIN. THIS CARD IS PREPRINTED WITH THE V.I. NUMBER, DEALER CODE AND CAMPAIGN NUMBER. UPON COMPLETION OF THE REPAIR, THE CARD SHOULD IMMEDIATELY BE COMPLETED, INCLUDING SERVICING DEALER CODE, REPAIR ORDER NUMBER,DATE OF REPAIR AND SIGNATURE OF PERSON VERIFYING THE REPAIRS AND FORWARDED TO SERVICE DEPARTMENT, PONTIAC MOTOR DIVISION, ONE PONTIAC PLAZA, PONTIAC, MICHIGAN 48053. ADDITIONAL CARDS AND CAMPAIGN LABELS ARE AVAILABLE FROM YOUR ZONE OFFICE SERVICE DEPARTMENT. DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER AS FOLLOWS: (NOTE: A COMPLETED WARRANTY CLAIMS IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.) WARRANTY CREDIT A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN. (LABOR) THE NEW LABOR OPERATIONS LISTED BELOW ARE ASSIGNED SPECIFICALLY FOR THIS CAMPAIGN. USE ONLY ONE OF THE LABOR OPERATIONS PER VEHICLE LABOR TROUBLE DESCRIPTION OPERATION CODE TIME INSPECT ENGINE CODE J602095 96 0.2 HOUR

INSPECT AND INSTALL CARB. KIT J602096 96 0.6 HOUR

IN ADDITION, DEALERS WILL AUTOMATICALLY RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATIVE DETAIL ASSOCIATED WITH THIS CAMPAIGN.

TROUBLE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

(PARTS)

THE NECESSARY CARBURETOR POWER PISTON SPRING REPLACEMENT KIT AND TUNE UP LABELS WILL BE FORWARDED TO DEALERS NO-CHARGE; THEREFORE, PART NO ERS ARE NOT TO BE LISTED ON THE WARRANTY CLAIM. LIST ONLY THE APPLICABLE AMOUNT SHOWN BELOW UNDER THE NET ITEM COLUMN. MATERIAL - $.75 NET AMOUNT CODE - M

THIS REPRESENTS 30% OF THE DEALER PRICE OF THE FURNISHED SERVICE PARTS.

(CREDITING)

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS SHOULD BE CLAIM TYPE 01, CONTAINING ALL INFORMATION REQUIRED FOR A REGULAR CLAIM, AND SHOULD LIST THE LABOR OPERATION(S) AS OUTLINED ABOVE. REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE CAMPAIGN WILL NOT BE PAID. REFER TO FIG. 11

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.