CAMPAIGN: POWERMASTER BRAKE SYSTEM/FAULTY PRESSURE SWITCH. Oldsmobile Custom Cruiser 1986

For 1990-2009 cars

# CAMPAIGN: POWERMASTER BRAKE SYSTEM/FAULTY PRESSURE SWITCH

#### SUBJECT: POWERMASTER BRAKE SYSTEM

#### MODELS AFFECTED: 1985 REGAL 3.8L TURBO (ENGINE VIN CODE 9) AND RPO LM9 BRAKES 1986-87 REGAL 3.8L TURBO (ENGINE VIN CODE 7) 1986 LESABRE AND ELECTR ESTATE WAGON 1986 CHEVROLET CAPRICE STATION WAGON 1986 PONTIAC PARISIENNE WAGON 1986 OLDSMOBILE CUSTOM CRUISER STATION WAGON

#### TO: ALL CHEVROLET DEALERS

** SEE BOTTOM OF CAMPAIGN FOR INFORMATION CONCERNING OTHER ** AFFECTED DIVISIONS.

GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1986 CHEVROLET "B" STATION WAGONS WITH POWERMASTER BRAKE SYSTEMS WERE BUILT WITH COMBINATION VALVES AND PRESSURE SWITCHES WHICH MAY BECOME FAULTY. IF LEFT UNCORRECTED THESE VEHICLES MAY EXPERIENCE A "HARD BRAKE PEDAL" OR "INCREASED BRAKE PEDAL TRAVEL". THESE CONDITIONS MAY BE CAUSED BY A CAST IRON COMBINATION VALVE ALLOWING AIR TO ENTER THE BRAKE SYSTEM OR BY A PRESSURE SWITCH LEAKING BRAKE FLUID.

TO PREVENT EITHER OF THE ABOVE CONDITIONS FROM OCCURING, VEHICLES WILL BE INSPECTED AND THOSE EQUIPPED WITH THE CAST IRON COMBINATION VALVE WILL RECEIVE A NEW BRASS COMBINATION VALVE. ALSO, PRESSURE SWITCHES WILL BE INSPECTED AND REPLACED IF NECESSARY.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1986 CHEVROLET "B" STATION WAGONS WITH POWERMASTER BRAKE SYSTEMS BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR MODEL PLANT FROM THROUGH

1986 "B" WAGON FAIRFAX GX100001 GX207019

INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VIN COMPUTER LISTINGS. COMPUTER LISTINGS CONTAIN THE COMPLETE VIN, OWNER NAME AND ADDRESS DATA, AND ARE FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. OWNER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH OWNERS INVOLVED IN THIS CAMPAIGN.

THESE LISTINGS 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 THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED.

OWNER NOTIFICATION

OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY CHEVROLET MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS 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 CORRECTION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN.

PARTS INFORMATION

PARTS REQUIRED TO COMPLETE THIS CAMPAIGN ARE TO BE OBTAINED FROM GMSPO. TO ENSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE, THEY SHOULD BE ORDERED FROM GMSPO ON A "C.I.O." ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ON AN ADVISE CODE 2.

QUANTITY/ PART NUMBER DESCRIPTION VEHICLE

25509419 BRASS COMBINATION VALVE 1

18018141 PRESSURE SWITCH (INCLUDES O-RING) 1

SERVICE PROCEDURE

1. INSPECT PRESSURE SWITCH. IF THE CURRENT PRESSURE SWITCH IS GRAY, MOVE ON TO STEP 2. IF THE CURRENT SWITCH IS BLACK, REMOVE AND REPLACE PRESSURE SWITCH ACCORDING TO THE PROCEDURE BELOW AND THEN MOVE ON TO STEP 2.

A. DEPRESSURIZE POWERMASTER UNIT BY TURNING IGNITION "OFF", AND APPLY AND RELEASE BRAKE PEDAL A MINIMUM OF TEN (10) TIMES USING APPROXIMATELY FIFTY (50) POUNDS OF FORCE ON PEDAL TO FULLY DEPLETE THE POWER ASSIST.

#### NOTICE: FAILURE TO FULLY DEPRESSURIZE POWERMASTER UNIT COULD RESULT IN BRAKE FLUID BEING SPRAYED ON SERVICE PERSONNEL AND COULD CAUSE DAMAGE TO PAINTED SURFACES.

B. DISCONNECT 3-WIRE ELECTRICAL CONNECTOR (FIG. 1, 40) FROM PRESSURE SWITCH (FIG. 1, 1).

C. REMOVE OLD PRESSURE SWITCH (FIG. 1, 1).

D. LUBRICATE NEW O-RING (FIG. 1, 2) WITH CLEAN, FRESH BRAKE FLUID AND INSTALL ON NEW PRESSURE SWITCH.

E. INSTALL NEW PRESSURE SWITCH (FIG. 1, 1), TIGHTEN TO 20-27 NM (15-20 LB. FT.).

#### NOTICE: TORQUE VALUES SPECIFIED ARE FOR DRY, UNLUBRICATED FASTENERS.

F. RECONNECT 3-WIRE ELECTRICAL CONNECTOR (FIG. 1, 40) TO PRESSURE SWITCH (FIG. 1, 1). BE SURE ELECTRICAL CONNECTOR IS SECURELY SEATED.

2. LOCATE COMBINATION VALVE (ON FRAME RAIL BELOW MASTER CYLINDER). IF THE CURRENT COMBINATION VALVE IS THE POTENTIALLY FAULTY CAST IRON VALVE TYPE THE VALVE MUST BE REPLACED WITH A BRASS VALVE TYPE BY FOLLOWING THE PROCEDURE BELOW. IF THE VEHICLE ALREADY HAS THE BRASS VALVE, THE COMBINATION VALVE DOES NOT NEED TO BE REPLACED. PROCEED TO STEP 3. FIGURE 2 ON THE NEXT PAGE ILLUSTRATES THE DIFFERENCES IN THE TWO VALVE TYPES.

A. REMOVE THE ELECTRICAL WARNING HARNESS CONNECTOR FROM THE PRESSURE DIFFERENTIAL SWITCH BY SQUEEZING THE ELIPTICAL-SHAPED PLASTIC LOCK RING AND PULLING UP. A PAIR OF PLIERS MAY AID IN REMOVING THE CONNECTOR.

B. DISCONNECT HYDRAULIC LINES AT COMBINATION VALVE. PLUG LINES TO PREVENT LOSS OF FLUID AND ENTRANCE OF DIRT.

C. REMOVE POTENTIALLY FAULTY CAST IRON COMBINATION VALVE.

D. INSTALL BRASS COMBINATION VALVE. TORQUE MOUNTING BOLTS TO 20 NM (14 LB. FT.).

E. CONNECT WARNING HARNESS SWITCH TO VALVE SWITCH TERMINAL.

F. REMOVE PLUGS AND CONNECT HYDRAULIC LINES AT COMBINATION VALVE. TORQUE LINES TO 24 NM (18 LB. FT.).

G. CONNECT ELECTRICAL WARNING HARNESS CONNECTOR TO PRESSURE CONTROL DIFFERENTIAL SWITCH.

H. BLEED ENTIRE BRAKE SYSTEM. DO NOT MOVE VEHICLE UNTIL A FIRM BRAKE PEDAL IS OBTAINED.

I. CHECK BRAKE LINES FOR PROPER CLEARANCES.

3. INSTALL CAMPAIGN IDENTIFICATION LABEL.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE CORRECTED 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 A BALL POINT 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.

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW: * FAILED PARTS LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP. HRS HRS

INSPECT - NO - -- -- SK-00 V6160 0.2 0.1 REPLACEMENT NEEDED PRESSURE SWITCH OR COMBINATION VALVE ------------------------------------------------------------------ INSPECT COMBO VALVE 1 18018141 ** SK-00 V6161 0.4 0.1 + PRESSURE SWITCH. REPLACE PRESSURE SWITCH ONLY. ------------------------------------------------------------------ INSPECT COMBO VALVE 1 25509419 ** SK-00 V6162 0.9 0.1 + PRESSURE SWITCH. REPLACE COMBO VALVE ONLY. ------------------------------------------------------------------ INSPECT/REPLACE 2 25509419 ** SK-00 V6163 1.2 0.1 COMBO VALVE AND PRESSURE SWITCH ------------------------------------------------------------------

* CAMPAIGN ADMINISTRATIVE ALLOWANCE

** THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSPO DEALER NET PRICE PLUS 30% OF ALL PARTS REQUIRED FOR THE REPAIR.

DEALERS WILL AUTOMATICALLY RECEIVE THE CORRECT LABOR AND MATERIAL ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED.

REFER TO THE CHEVROLET CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUCT CAMPAIGN CLAIM SUBMISSION.

REIMBURSEMENT

CUSTOMER REQUESTS FOR REIMBURSEMENT OF PRIOR REPLACEMENT OF THE POWERMASTER BRAKE ASSEMBLY ARE TO BE SUBMITTED ACCORDING TO THE FORMS AND INSTRUCTIONS INCLUDED IN THIS BULLETIN (ADDITIONAL COPIES TO BE REPRODUCED LOCALLY) WITHIN 3 MONTHS (90 DAYS) OF THE DATE OF THEIR OWNER LETTER. OWNERS MUST SUBMIT ORIGINAL DOCUMENTATION THAT REASONABLY CONFIRMS THE AMOUNT OF UNREIMBURSED REPAIR EXPENSES, A DESCRIPTION OF THE REPAIR, THE DATE OF THE REPAIR, AND THE PERSON OR ENTITY PERFORMING THE REPAIR TO RECEIVE REIMBURSEMENT.

COPYRIGHT 1990 CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

** BUICK INFORMATION ONLY:

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1985, 1986 AND 1987 REGAL 3.8L TURBO ENGINE COUPES AND 1986 LESABRE AND ELECTRA ESTATE WAGONS WITH POWERMASTER BRAKE SYSTEM BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS

YEAR MODEL PLANT FROM THROUGH 1985 REGAL TURBO COUPE PONTIAC FP400004 FP427709 1986 REGAL TURBO COUPE PONTIAC GP201039 GP459261 1986 ESTATE WAGON FAIRFAX GX400001 GX418126 1987 REGAL TURBO COUPE PONTIAC HP400001 HP465289

BUICK CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW: * FAILED PARTS LABOR LAB OTH DLR. OPER. PC PART NO. ALLOW CC-FC OP. HRS HRS MTL TWG ------------------------------------------------------------------ - -- -- 96 V6160 0.2 0.1* ----

#### INSPECT - NO REPLACEMENT NEEDED - PRESSURE SWITCH OR COMBINATION VALUE

1 18018141 ** 96 V6161 0.4 0.1* ----

#### INSPECT AND REPLACE PRESSURE SWITCH ONLY (ALL INVOLVED VEHICLES)

1 25509419 ** 96 V6162 0.9 0.1* 2.86***

#### INSPECT AND REPLACE COMVINATION VALUE (1986 LESABRE AND ELECTRA ESTATE

2 25509419 ** 96 V6163 1.2 0.1* 2.86***

INSPECT AND REPLACE PRESSURE SWITCH AND COMVINATION VALUE (1986 LESABRE AND ELECTRA ESTATE WAGON ONLY) ------------------------------------------------------------------ - -- -- 96 T1640 (SEE INSTRUCTIONS FOR REIMBURSEMENT) REIMBURSEMENT FOR PREVIOUSLY CUSTOMER PAID REPAIRS ------------------------------------------------------------------

* DEALER ADMINISTRATION ALLOWANCE ** LIST CURRENT DEALER PRICE, PLUS 30% *** MATERIAL ALLOWANCE FOR HYDRAULIC BRAKE FLUID (DOT 3)

BUICK REQUEST FOR REIMBURSEMENT INSTRUCTIONS

1. CUSTOMER PRESENTS DEALER WITH ORIGINAL PAID RECEIPTS COVERING REPAIRS.

2. DEALER COMPETES A REPAIR ORDER (R.O.) SHOWING THE FOLLOWING - REPAIR ORDER DATA - VEHICLE IDENTIFICATION NUMBER - CURRENT MILEAGE - OWNER'S ADDRESS - ATTACHES ORIGINAL OWNER'S OR DEALER'S PAID INVOICES/RECEIPTS REPAIR - USE LABOR OPERATION NUMBER T1640 AND FAILURE CODE 96 - ENTER TOTAL OF REIMBURSEMENT BASED ON 100% OF OWNERS EXPENSE

3. OWNER SIGNS THE REPAIR ORDER AS ACKNOWLEDGEMENT OF REQUESTED REIMBURSEMENT AMOUNT.

4. OWNER IS GIVEN A COPY OF REPAIR ORDER.

5. DEALER ASSIGNS A WARRANTY MANAGEMENT SYSTEM (WMS) AUTHORIZATION CODE TO THE CLAIM AND ENTERS IT ON THE WMS AUTHORIZATION LOG.

6. THE DEALER SUBMITS A CLAIM TO BUICK FOR PROCESSING

7. DEALER ISSUES THE OWNER A REIMBURSEMENT CHECK FOR THE APPROVED AMOUNT. THE CHECK NUMBER MUST BE ENTERED ON THE REPAIR ORDER AND A COPY OF THE CHECK MUST BE ATTACHED TO ORIGINAL PAID INVOICES RECEIPTS.

8. ALL SUPPORTING DOCUMENTATION MUST BE AVAILABLE FOR REVIEW BY BUICK

#### NOTICE: REFER TO BUICK SERVICE POLICIES AND PROCEDURE MANUAL, SECTION 1.6.11 FOR SPECIFIC PROCEDURES FOR CUSTOMER REIMBURSEMENT VERIFICATION.

IN THE EVENT THE DEALER SERVICE MANAGER AND THE OWNER CANNOT REACH AGREEMENT ON AMOUNT ELIGIBLE FOR REIMBURSEMENT AFTER REVIEW OF INVOICES/RECEIPTS, THE ZONE/BRANCH SHOULD BE CONTACTED FOR DETERMINATION OF COVERED EXPENSES. IN SUCH CASES, AN EXPLANATION SHOULD BE INCLUDED ON THE R.O.

** PONTIAC INFORMATION ONLY:

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1986 PONTIAC PARISIENNE STATION WAGONS WITH POWERMASTER BRAKE SYSTEMS BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR MODEL FROM THROUGH 1986 FAIRFAX GX200005 GX285088

PONTIAC CLAIM INFORMATION:

A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VEHICLE. A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

OTHER* FAILURE LABOR LABOR LABOR OPERATION CODE OPERATION HOURS HOURS -------------- --------- --------- ------- -------- INSPECT PRESSURE SWITCH AND COMBINATION VALUVE-NO REPLACEMENTS NEEDED 96 V6160 0.2 0.1

INSPECT COMBINATION VALVE AND PRESSURE SWITCH-REPLACE PRESSURE SWITCH ONLY 96 V6161 0.4 0.1

INSPECT COMBINATION VALVE AND PRESSURE SWITCH-REPLACE COMBINATION VALVE ONLY 96 V6162 0.9 0.1

INSPECT/REPLACE COMBINATION VALVE AND PRESSURE SWITCH 96 V6163 1.2 0.1

OWNER REIMBURSEMENT FOR PRIOR REPLACEMENT OF THE POWERMASTER BRAKE ASSEMBLY, COMBINATION VALVE, AND/OR PRESSURE SWITCH 95 T1640 --- ---

* IN ADDITION, DEALERSHIPS WILL RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATIVE SERVICES ASSOCIATED WITH THIS CAMPAIGN. THE 0.1 HOURS ALLOWANCE IS TO BE ENTERED IN THE 'OTHER LABOR HOURS' FIELD WITH EACH CAMPAIGN REPAIR LISTED FOR CREDIT. THIS ENTRY WILL NOT REQUIRE AUTHORIZATION.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

PARTS REQUIRED ARE TO BE LISTED IN YOUR WARRANTY CLAIM IN THE NORMAL MANNER. PARTS WILL BE CREDITED AT DEALER NET PLUS 30% DEALER HANDLING ALLOWANCE.

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIM MUST CONTAIN ALL INFORMATION REQUIRED AND SHOULD LIST THE LABOR OPERATION AS OUTLINED.

** OLDSMOBILE INFORMATION ONLY:

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1986 PONTIAC PARISIENNE STATION WAGONS WITH POWERMASTER BRAKE SYSTEMS BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR MODEL FROM THROUGH MODEL NAME 1986 'B' WAGON GX200005 GX285088 CUSTOMER CRUISER

OLDSMOBILE CLAIM INFORMATION:

SUBMIT CLAIMS USING NO MORE THAN ONE OF THE 'V' LABOR-OPS BELOW FOR EACH VEHICLE. AS APPROPRIATE, BOTH A 'T' LABOR OP AND ONE 'V' LABOR- OP MAN BE SUBMITTED ON A VEHICLE.

FAILURE LABOR LABOR OPERATION CODE OPERATION HOURS TOT-PTS -------------- --------- --------- ------- ------- INSPECT PRESSURE SWITCH OR COMBINATION VALUVE-NO REPLACEMENTS NEEDED 96 V6160 0.2*

INSPECT COMBINATION VALVE AND PRESSURE SWITCH-REPLACE PRESSURE SWITCH ONLY 96 V6161 0.4*

INSPECT COMBINATION VALVE AND PRESSURE SWITCH-REPLACE COMBINATION VALVE ONLY 96 V6162 0.9*

INSPECT/REPLACE COMBINATION VALVE AND PRESSURE SWITCH 96 V6163 1.2*

OWNER REIMBURSEMENT FOR PRIOR REPLACEMENT OF THE POWERMASTER BRAKE ASSEMBLY, COMBINATION VALVE, AND/OR PRESSURE SWITCH (PRIOR ZONE AUTHORIZATION REQUIRED 96 T1640 ---

* .1 HOUR FOR CLERICAL ADMINISTRATION MAY BE ADDED TO THE PUBLISHED LABOR HOURS.

PARTS ALLOWANCE: CURRENT DEALER PRICE, PLUS 30% HANDLING ALLOWANCE.

THE COST OF BRAKE FLUID MAY BE APPLIED FOR IN THE USUAL MANNER.

**GENERAL MOTERS DISCLAIMER***

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.