Customer Satisfaction 00004 - Upper Radiator Hose May Contact Battery Tray

General Motors has decided that certain 1998-2000 Chevrolet Cavalier and Pontiac Sunfire vehicles equipped with 2.2L engines (RPO LN2; VIN 4) may exhibit a condition in which the upper radiator hose contacts the battery tray. Contact between the radiator hose and the battery tray can damage the radiator hose and could result in an engine coolant leak, with a low coolant telltale (warning lamp) illuminating on the instrument cluster. If the vehicle is driven extensively with low coolant, the engine could overheat and be damaged.

To prevent the possibility of this condition occurring, dealers are to inspect the upper radiator hose for the presence of a protective conduit. If the protective conduit is present, no further repair/inspection is necessary. If the protective conduit is not present, dealers are to inspect the upper radiator hose for any signs of abrasion or damage. If there are no signs of contact, or only light, superficial rubbing has occurred, dealers are to install a piece of protective conduit to the upper radiator hose. If the radiator hose exhibits severe damage such as a deep cut or abrasion so that reinforcement cording/threads are exposed, dealers are to replace the damaged hose with a hose equipped with the protective conduit.

Involved are certain 1998-2000 Chevrolet Cavalier and Pontiac Sunfire vehicles equipped with 2.2L (RPO LN2; VIN 4) engines and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or GM Access Screen (Canada only) or DSC Screen 445 (IPC only) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Important: An initial supply of protective conduit required to complete this campaign will be pre-shipped to involved dealers of record. This pre-shipment will begin the week of April 3, 2000. Pre-shipped parts will be charged to dealer's open parts account.

Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: It is estimated that only 10% of involved vehicles will require radiator hose replacement. Please order parts accordingly.

1. Inspect the upper radiator hose for the presence of a piece of protective conduit on the hose. Refer to the illustration.

•	If the protective conduit is present, no repair is required. Proceed to Step 3.

•	If the protective conduit is not present, proceed to Step 2.

2. Inspect the upper radiator hose for signs of abrasion or damage.

•	If there is no abrasion, or only light/superficial abrasion, install protective conduit, P/N 22664960, to the radiator hose in the area adjacent to the battery tray (1), with the seam of the conduit faced away from the battery tray. Refer to the illustration.

•

If the radiator hose has a deep cut or abrasion so that reinforcement cording/threads are visible, replace the hose with P/N 22618825, and install protective conduit, P/N 22664960, to the radiator hose in the area adjacent to the battery tray (1), with the seam of the conduit faced away from the battery tray. Refer to the illustration.

3. Install the GM Campaign Identification Label.

For US and IPC

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Campaign Claim Submission.

Customer requests for reimbursement of previously paid repairs to correct a damaged radiator hose are to be submitted by April 30, 2001 (this time limitation may be longer depending upon the law in your state/province/country).

Consideration for reimbursement will be allowed only if genuine General Motors parts were used. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM service policies and procedures manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

For US and Canada

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

For IPC

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached suggested dealer letter.

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

Dear Chevrolet Cavalier/Pontiac Sunfire Customer:

We want your experience owning your Cavalier/Sunfire to be better than any other you have had ... which is why we are writing.

We have learned that the upper radiator hose on your vehicle may contact the battery tray. Contact between the radiator hose and the battery tray can damage the radiator hose and could result in an engine coolant leak, with a low coolant telltale (warning lamp) illuminating on the instrument cluster. If the vehicle is driven extensively with low coolant, the engine could overheat and be damaged.

We've advised our dealers to install a protective conduit to the upper radiator hose. Any damaged radiator hoses will be replaced, and the protective conduit will also be installed.

Your vehicle may have been recalled before this condition. We are recalling it again because a protective conduit was not installed on all vehicles in the previous recall, and we now know that the conduit is necessary.

We recommend that you contact your Chevrolet/Pontiac dealer to arrange a service date and to assure parts availability.

The attached customer reply card identifies your vehicle. Presenting this card to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the attached and mailing it in the postage-paid envelope.

If you experience any trouble scheduling your vehicle or you have any questions regarding this recall action, please contact your Chevrolet/Pontiac dealer or the Chevrolet/Pontiac Customer Assistance Center at the listed number below:

We sincerely regret any inconvenience this causes you. Also, we want you to know that we will continue to do everything we can to ensure that you are completely satisfied with your [Cavalier and with Chevrolet]/[Sunfire and with Pontiac].

Chevrolet/Pontiac Motor Division

General Motors Corporation

Enclosure