SPECIAL POLICY: A/C HIGH SIDE SERVICE FITTING

MODELS AFFECTED 1988 SUNBIRD WITH 2.0L OHC (LT2, VIN CODE "K") ENGINE AND AIR CONDITIONING

TO: ALL PONTIAC DEALERS

General Motors has determined that some 1988 Sunbirds equipped with air conditioning are missing the High Side Service Fitting. This affects diagnostics of the air conditioning system if service is required.

Pontiac's concern in this instance is not with the operation of the air conditioning or with any other vehicle system. Rather, this bulletin addresses procedures dealer service technicians will follow when diagnosing random air conditioning complaints in the future.

For 1988 Sunbird production, the orifice tube in the air conditioning system was moved; however, the High Side Service Fitting was not relocated on early built vehicles with the consequence that both the High Side and Low Side Service Fittings were on the low pressure side of the orifice tube.

If analysis of an air conditioning refrigeration complaint requires reading high side pressure in early built 1988 Sunbirds with 2.0L (VIN Code "K") engines, it will be necessary to replace the Hose Assembly - A/C Compressor and Condenser, with a new assembly, Part Number 22545477. The new assembly incorporates a Shrader-type valve fitting for reading the high side pressure.

VEHICLES INVOLVED

1988 Sunbird models with Air Conditioning and 2.OL OHC (VIN Code "K") engines built from the start of 1988 model year production through and including VIN J7533343.

SPECIAL POLICY ADJUSTMENT

General Motors will replace the Hose Assembly - A/C Compressor and Condenser, at the time first use of the High Side Service Fitting is required to diagnose an air conditioning refrigeration complaint. This special policy adjustment is effective through the last day of September 1994.

This "Special Policy" bulletin should be filed in the three ring binder previously furnished to the dealer by General Motors.

SERVICE PROCEDURE

To replace the Hose Assembly - A/C Compressor and Condenser, refer to the 1988 Sunbird Service Manual, Sections 1B and 1B1, for proper service information.

If the Hose Assembly - A/C Compressor and Condenser has been previously replaced with a correct part, a pressure fitting will be found on the high pressure "vapor" line which runs between the A/C Compressor and the Condenser at a point near the Condenser inlet (see Illustration). In that case, replacement of the Hose Assembly - A/C Compressor and Condenser under the terms of this special policy would not be necessary.

When taking low side pressure readings, use the Shrader valve fitting at the Accumulator Assembly only. Do not use the extra fitting near the condenser on the Tube Assembly - A/C Evaporator (pipe conveying liquid Refrigerant-12 from the condenser to the evaporator). See Illustration.

PARTS INFORMATION

Use the following part numbers:

QUANTITY DESCRIPTION PART NUMBER PER VEHICLE ----------- ----------- ----------- Hose Assembly - A/C Compressor and Condenser 22545477 1

Seal, Suction Discharge Ports (O-rings at A/C Compressor) 5887997 2

Refrigerant-12 As required

The following seals (O-rings) are shipped already installed on the Hose Assembly - A/C Compressor Condenser. However, if missing, use:

O-ring Connector - Refrigerant (at A/C Accumulator outlet fitting) 3094216 Maximum 1, If required

Seal, A/C Condenser Fitting (O-ring) (at Condenser end of Discharge Line) 3094214 Maximum 1, If required

WARRANTY CLAIM INFORMATION -------------------------- FAILURE LABOR LABOR DESCRIPTION CODE OPERATION HOURS ----------- ---- --------- ----- *Replace Hose Assembly - A/C Compressor and Condenser and Discharge/Charge A/C System 95 T4632 .8 **Owner Reimbursement for Previous Repairs 95 T4631

Parts Allowance: Current dealer price, plus 30% handling allowance.

*An allowance for Refrigerant-12 may be applied for in the normal manner; list two (2) "parts" in the "TOT-PTS" column.

**Total reimbursement amount requested should be shown in the sublet column.

REIMBURSEMENT

Claims for customer reimbursement of previously paid repairs are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation listed under the Claim section of this bulletin. Reimbursement amounts of $150.00 or less can be processed by the dealer. If the amount exceeds $150.00, claims must be forwarded to and processed by the Zone Office.

Reimbursement shall be only for the reasonable cost of parts and labor to replace the Hose Assembly - A/C Compressor and Condenser, including discharge/charge of the A/C system.

To receive reimbursement for nonreimbursed repair expense due to a previous replacement of the Hose Assembly - A/C Compressor and Condenser, for the purpose of reading pressures at the High Side Service Fitting for diagnosis of A/C refrigerant system complaints, eligible owners must submit claims to an authorized Pontiac dealer no later than September 30, 1994.

Claims must be supported by documentation that reasonably: (1) discloses the associated repair expenses incurred for a replacement of the Hose Assembly - A/C Compressor and Condenser, for the purpose of reading pressures at the High Side Service Fitting for diagnosis of A/C refrigerant system complaints; (2) identifies the entity or person who performed the repairs; (3) identifies the date of such repairs; (4) discloses the amount of nonreimbursed repair expenses actually paid by the owner. Owners must provide original or certified receipts that are to be retained in the dealer files.

Claims for customer reimbursement on previously paid repairs are to be submitted according to the Warranty Claim Information Instructions. Use the "Owner Reimbursement" labor operation and list all owner expenses concerning previous repairs in the net items column of the warranty claim.

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.