CAMPAIGN:OVERHEATING OF THE BATTERY CABLE CONNECTION

SUBJECT: ELECTRICAL CENTRE BATTERY STUD

Models: 1994 Chevrolet Caprice SEO Vehicles (Police Cars, Taxi and Special Service Wagons)

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1994 Chevrolet Caprice Police, Taxi and Special Service Wagon vehicles may experience overheating of the battery cable connection at the underhood electrical center stud. This may cause melting of the battery cable plastic cover, the plastic stud housing and/or the stud itself, resulting in loss of vehicle power.

To correct this condition, dealers are to install a new battery cable stud made of improved material.

VEHICLES INVOLVED:

Involved are certain 1994 Chevrolet Caprice Police Cars (SEO 9C1), Special Service Station Wagons (SEO 1A2) and Taxi Vehicles (SEO 9C6) built with the following VIN breakpoints:

Year Model Plant Plant Code From Through

1994 B-Car Arlington R SOP EOP

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign MUST be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaip on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

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

CAMPAIGN PROCEDURE

Refer to Section 4 of the Service PoHcies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFCATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ---------------------------------------------------------------------------- 11516161 Nut, Stud Assy 1 12161130 Stud Assembly, Battery Cable 1 12146183 Cover, Electrical Centre Stud As Required 12129481 Bussbar, (65 mm, Inboard side, As Required Terminal Cavity L1 & L3) 12146182 Bussbar, (75 mm, Outboard side As Required Terminal Cavity L2 & L4)

NOTICE: IT IS ANTICIPATED THAT LESS THAN 23% OF THE ELECTRICAL CENTRE STUD COVERS WILL NEED REPLACEMENT AND LESS THAN 5% OF THE BUSSBARS WILL REQUIRE REPLACEMENT. PLEASE ORDER YOUR PARTS ACCORDINGLY.

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaip claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Replace Stud/Nut .6

3A Replace Stud/Nut & Cover .6

4A Replace Stud/Nut, Cover & 1 Bussbar .6 (Inboard Side)

5A Replace Stud/Nut, Cover & 1 Bussbar .6 (Outboard Side)

9A Replace Stud/Nut Cover & 2 Bussbars .6 (Inboard/Outboard Side)

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 40% to cover parts handling.

SERVICE PROCEDURE:

1. Disconnect negative battery cable from battery. Be sure all auxiliary devices (police radios, radars, etc.) are turned off prior to disconnecting battery. Technicians may wish to consult with vehicle driver on proper deactivation procedures for these devices. Radio settings should also be noted prior to disconnecting battery so they may be reset later.

2. Remove "AUX. BATT. POS. COVER" (Figure 1) from electrical centre stud. Electrical centre and stud is located on top of right hand wheelhouse, just ahead of the front of dash.

3. Remove stud nut (not to be reinstalled) and positive battery cable from stud (Figure 1).

4. Remove two nuts holding the electrical centre to wheelhouse.

5. Remove top cover from electrical centre.

6. Remove electrical centre from plastic bracket. Use a small screwdriver to release the retaining tabs (Figure 2).

7. Remove the small shorting prevention cover from the lower portion of the stud assembly (see Figure 3).

8. Remove bolt securing ring terminals to bottom portion of stud assembly (Figure 2).

9. Remove 4 large Maxi-fuses.

10. Remove Terminal Position Assurance "TPA" closest to the stud (Figure 4).

11. Use a small flat blade screwdriver to release the four terminals securing the two bussbars in the electrical centre (Figure 5). Pull the bussbar out the bottom.

12. Release the retaining tab, then slide stud assembly from electrical centre (Figure 6).

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer

General Motors of Canada has determined that certain 1994 Chevrolet Caprice Police, Taxi and Special Service Wagon vehicles may experience overheating of the battery cable connection at the underhood electrical centre stud. This may cause melting of the battery cable plastic cover, the plastic stud housing and/or the stud itself, resulting in loss of vehicle power.

To correct this condition, your dealer will install a new battery cable stud made of improved material.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

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

Customer Support Department General Motors of Canada Limited

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.