CAMPAIGN: MASTER CYLINDER BRAKE PROPORTIONER. Chevrolet Cavalier 1983

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within 60 days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owners are being instructed to contact the nearest Chevrolet Zone Office if their dealer does not remedy the condition within five days of the agreed service date. If the condition is not remedied within a reasonable time, they are instructed how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists on some 1983 Chevrolet Celebrity, Citation and Cavalier Model Cars. The brake proportioner valves used on some of these vehicles may break and separate from the master cylinder. This would result in a brake fluid leak and a partial loss of the brake system. These vehicles are equipped with a dual braking system; part of the system will still work and allow the vehicle to be stopped, but over a greater distance. Partial loss of the brake system at a time when minimum stopping distance is required could result in a vehicle crash without prior warning.

VEHICLES INVOLVED

Involved are certain 1983 Chevrolet Celebrity, Citation and Cavalier Models within the following breakpoints:

Plant Model From Through ----- ----- ---- ------- Oklahoma City Celebrity D6804393 D6822143 Oshawa Celebrity D1808523 D1810818 " D1814224 D1821141 " D1824695 D1825832 " D1829104 D1832015 " D1835303 D1835695 Oklahoma City Citation D6105795 D6123727 Tarrytown Citation DT116759 DT117791 " DT118101 DT130791 " DT131329 DT131796 " DT132331 DT134312 Lordstown Cavalier D7112022 D7143146 Janesville Cavalier DJ112500 DJ140000

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 the 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 was not shipped any involved vehicles.

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 subiect 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 modification according to instructions contained in this bulletin.

PARTS INFORMATION

The parts when required are to be obtained from WDDGM. Refer to chart to obtain correct valve for a vehicle.

Part No. ID Part No. ID Front Code Rear Code Model Usage 10mm On Valve 13MM On Valve ----- ----- ---- -------- ---- -------- Celebrity H.D. Brakes 18009966 (FJ) 18009967 (RJ) Celebrity Without H D. 18008570 (FK) 18008571 (RK) Brakes Citation All 18008570 (FK) 18008571 (RK) Cavalier All 18009966 (FJ) 18009967 (RJ)

To ensure this part will be obtained as soon as possible, it should be ordered on a C.I.O. order with no special instruction code, but order on an advise code (2).

Parts removed from the involved vehicles are to be retained by the dealer in accordance with the current Service Policies and Procedures Manual.

SERVICE PROCEDURE

Part 1

Inspection Of Proportioner Valve

1. Open vehicle hood and cover left-front fender.

2. It may be necessary to clean the ends of the front and rear brake proportioner valves located in the master cylinder for inspection. If this is required, wipe valves clean using brake fluid. Do not use a solvent to clean the valves, as it could enter the small notches (vents) of valves and cause damage to the internal seals of the valves.

3. Inspect the front and rear proportioner valves to determine if either one or both of the valves need to be replaced. Refer to Figure 1. Use a magnifying glass to identify the valves. Proportioner valves from three different sources were used interchangeably; therefore, both front and rear valves will not require replacement in all cases.

4. Replace all proportioner valves, as instructed in Part II of this procedure, that are of design shown View A of Figure 1. If the valve identification cannot be accurately determined, or there is a question on identification, valve(s) should be replaced.

Special care should be taken to ensure that specified torque valves are used when installing new proportioner valves.

5. If valves are the design shown in View B or View C of Figure 1, no further action is required except to install a campaign identification label as instructed in Part III of this procedure.

Part II

Replacemnet of Proportioner Valve

1. Refer to Parts Information section of this bulletin to obtain correct part number proportioner valve(s) for vehicle.

2. Place material under proportioner valve connections to protect under hood parts from brake fluid.

3. Refer to Figure 2 for valve replacement procedure.

4. Bleed master cylinder and proportioner valve connections as follows:

a. If the car is equipped with power brakes, remove the vacuum reserve by applying the brakes several times.

b. After installing new valve(s), reconnect all removed brake pipe connectors.

c. Fill the master cylinder reservoirs with brake fluid and keep at least one-half full of fluid during the bleeding operation.

d. Remove left front pipe connector. Refer to Figure 3. When brake fluid begins to flow from left front master cylinder port, reconnect left front brake pipe and tighten to specified torque.

e. Slowly apply brake pedal until firm.

f. Loosen left front brake pipe connector to purge air. Retighten connector and slowly release brake pedal. Wait 15 seconds.

g. Repeat (e) and (f) until all air is purged. (IMPORTANT: COMPLETE (g) BEFORE ATTEMPTING (h) AND (i).)

h. Repeat (e) and now loosen right front brake pipe connector to purge air. When brake fluid begins to flow from connector, retighten connector to specified torque and slowly release brake pedal. Wait 15 seconds. Refer to Figure 3.

i. Repeat (h) until all air is purged.

5. Check the brake pedal for "sponginess" and brake warning light for indication of unbalanced pressure. Repeat bleeding operation to correct. Do not move car until a firm brake pedal is obtained.

6. Tighten all tube nuts to specified torque and correct any leaks, if required.

7. Fill master cylinder.

8. Install a campaign identification label.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

Parts Failed Parts Failure Labor Labor *Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ---- ---------- ----- ----- ------ 00 V1820 .2 .1

Description: Inspect brake proportioner valves according to the instructions outlined in this bulletin. No further action required.

** Parts Failed Parts Failure Labor Labor *Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ---- --------- ----- ----- ------ 1 18009966 00 V1821 .3 .1 1.02

Description: Inspect and replace one(l) proportioner valve according to the instructions outlined in this bulletin.

** Parts Failed Parts Failure Labor Labor *Other Net Count Part No. Allowance Code Operation Hours Hours Amount ----- --------- --------- ---- --------- ----- ----- ------ 2 18008570 00 V1822 .4 .1 1.02

Description: Inspect and replace two (2) proportioner valves according to the instructions outlined in this bulletin.

*Campaign Administrative Allowance.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

**The $1.02 identified in the "Net Amount Column" represents the brake fluid allowance for labor operation V1821 or V1822.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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 digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint 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.

ADMINISTRATIVE PROCEDURES

REFER TO THE CURRENT CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL AND CLAIMS PROCESSING MANUAL FOR CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURES.

This notice is sent to you in accordance with the requirements of the National Traffic and motor Vehicle Safety Act.

To prevent this from occurring on your vehicle, please contact your Chevrolet Dealer to arrange a service date. Your dealer will inspect the brake proportioner valves. Suspect valves will be replaced with new ones. This service will be done at no charge.

Instructions for Completing this service have been sent to your Chevrolet Dealer. It is estimated that parts will be available approximately October 17, 1983. The labor time to inspect your car is about 10 minutes. Valve replacement, if required, will take an additional 20 minutes. Please allow additional time for the dealer to process your vehicle.

Until you have had an opportunity to have this service completed, you should be alert for an increase in brake pedal travel during brake application and illumination of the brake warning light on the dash panel.

Your Chevrolet Dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five days, we recommend you contact the nearest Chevrolet Zone Office, either in person or by telephone. The Zone Office will assist you and the dealer in getting your vehicle corrected. The locations and telephone numbers of the Zone Offices are listed in your Owner's Manual.

After contacting your dealer and the Zone Office, if you are still not satisfied that we have done our best to remedy this condition without charge within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W. Washington, D.C. 20590, or call 800-424-9393 (Washington, D.C. residents use 426-0123).

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid owner 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 safety and continued satisfaction with our products.

Object Number: 80635 Size: FS

Object Number: 87287 Size: MF

Object Number: 86983 Size: LF

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.