CAMPAIGN: HEATER OUTLET HOSE ASST. HOSE ROUTING/ABRASION. Chevrolet Caprice 1992

Subject: PRODUCT CAMPAIGN 92Cl4 - HEATER OUTLET HOSE ASSEMBLY

Model and Year: 1992 CHEVROLET CAPRICE

To: All Chevrolet Dealers

General Motors has determined that certain 1992 Chevrolet Caprice model vehicles may have been built with the heater outlet hose routed above the heater inlet hose assembly allowing the heater inlet hose to contact the A.I.R piping. This contact may cause the heater inlet hose to become damaged by either abrasion or heat.

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the hose assembly if necessary.

INVOLVED VEHICLES

Involved are certain 1992 Chevrolet Caprice model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1992 B-Car Willow Run "W" NW111002 NW115827

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, 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

Although most vehicles involved in this campaign will not require any parts to complete this campaign, a very small number of vehicles could experience a severely chafed and/or worn inlet hose. If a vehicle is found which requires a new inlet hose, order the appropriate replacement hose from your General Motors Parts and Illustration Guide.

DUE TO THE SMALL NUMBER OF INLET HOSES REQUIRED (AND TO ASSURE AVAILABILITY OF PARTS FOR VEHICLES WHICH EXPERIENCE A SEVERELY CHAFED OR WORN INLET HOSE) DO NOT ORDER AN INLET HOSE UNLESS YOU HAVE INSPECTED AND DETERMINED THAT A VEHICLE HAS A SEVERELY WORN OR CHAFED INLET HOSE.

SERVICE PROCEDURE

INSPECTION PROCEDURE

Determine if heater inlet hose is routed below heater outlet hose as shown in "INCORRECT" illustration on page 3.

If heater inlet hose is installed under heater outlet hose, "REROUTING PROCEDURE" below must be performed.

If heater inlet hose is routed as shown in "CORRECT" illustration (page 3), no further action is necessary. Install Campaign Identification Label and return vehicle to customer or to dealer stock.

REROUTING PROCEDURE

1. Park vehicle on a level surface.

2. Remove pressure cap from radiator when engine is cool by:

- Slowly rotating counterclockwise to detent. (Do not press down while rotating).

- Wait until any left over pressure (indicated by a hissing sound) is released.

- After all hissing stops, press down on cap while continuing to rotate counterclockwise.

NOTICE: TO AVOID BEING BURNED, DO NOT REMOVE RADIATOR CAP WHILE ENGINE IS AT NORMAL OPERATING TEMPERATURE. COOLING SYSTEM WILL RELEASE SCALDING FLUID AND STEAM UNDER PRESSURE IF CAP IS REMOVED WHILE ENGINE AND RADIATOR ARE STILL HOT.

3. With a clean drain pan in place, open radiator drain valve.

4. Once enough fluid has drained out of radiator:

- Remove screw from heater outlet hose bracket to cowl panel.

- Remove heater outlet hose from heater core tube (inboard tube) by squeezing both release tabs of quick connect f itting at base of heater core tube and pulling on pipe to disengage fitting (see quick connect fitting illustration on page 3).

5. Inspect inlet hose for signs of severe chafing and/or wear-through (note that very few hoses are expected to be chafed or worn). If inlet hose does require replacement, install new hose following Heater Water Flow Control Valve Assembly procedures on page 1B-26 of 1992 Chevrolet Caprice Sedan/Wagon Service Manual.

6. Reposition outlet hose properly (under heater inlet hose), align orientation tabs with groves and push hose fitting in place then pull back on hose to ensure proper installation of connector.

NOTICE: Make sure two "O" rings and nylon spacers are in position in quick connect fitting prior to reinstalling outlet hose connection.

Also, make certain quick connect f itting orientation tabs are aligned correctly before connecting quick connect fitting. If quick connect fitting is incorrectly connected, coolant leakage and damage to parts may occur. The quick connect f itting must be pushed on then pulled back to verify proper connector engagement.

Do not rely on an audible click or visual verification to check for a proper connection. If it is necessary to repair quick connect connector use approved service kit which can be obtained from GMSPO.

7. Install outlet hose bracket and screw to cowl panel.

8. Check outboard inlet hose for clearance to A.I.R. pipe. Also, check to assure protective sleeve on heater outlet hose is under heater inlet hose.

9. Close radiator drain valve.

10. Pour drained coolant into radiator until tank is filled.

11. Start engine and run 5 minutes (or until inlet hose is hot).

12. Top off radiator with coolant and install cap.

13. Fill coolant recovery reservoir to hot line with coolant.

NOTICE: "Coolant" is 50/50 mix of water and ethylene glycol.

14. 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 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.

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. Additional "Campaign Identification Labels" can be obtained from DAC. Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated on the next page:

FAILED PARTS CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW 0P HRS HRS AMT ------------------------------------------------------------------------------

Inspect/No Further - -- -- SK-00 V7360 0.2 0.1 Action Required

Inspect/Reroute outlet Hose - Inlet - -- -- SK-00 V7361 0.4 0.1 Hose Not Chafed

Inspect/Reroute Outlet Hose - Inlet 1 10165021 SK-00 V7362 0.6 0.1 Hose Replaced

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 3096 of all parts required for the repair.

*** The $#.## in the "Net Amount" column represents dealer cost plus 30% for 1 pint of coolant required for labor operations V7361 and V7362.

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.

Dear Chevrolet Caprice Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

WHAT WE WILL DO

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the hose if necessary. This service will be provided at no charge to you.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this inspection/correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Object Number: 78894 Size: FS

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.