CAMPAIGN: PULSAIR PIPE HC/CO EMISSIONS REPLACE PULSAIR PIPE

Model and Year: 1982 CHEVROLET CHEVETTE MODELS EQUIPPED WITH RPO L17 (1.6L L4) ENGINE - AUTOMATIC TRANSMISSION AND FEDERAL EMISSION SYSTEM

TO: ALL CHEVROLET DEALERS

General Motors has determined that certain 1982 Chevrolet Chevette models equipped with RPO L17 (1.6L L4) engine, automatic transmission and Federal emission system may have certain deficiencies in the emission control system which may result in increased tailpipe hydrocarbon (HC) and carbon monoxide (CO) emissions.

The cause may be attributed to internal pulsair pipe corrosion (and even- tual perforation causing an exhaust leak), which may result in increased emissions. The carburetor flow characteristics may shift in the rich direction with mileage, further resulting in increased emissions.

VEHICLES INVOLVED

Certain 1982 Chevrolet Chevette models equipped with RPO L17 (1.6L L4) engine, automatic transmission and Federal emission system within the following vehicle parameters:

PLANT FROM THROUGH ----- ---- ------- Lakewood CA100001 CA175260

Wilmington CY100001 CY257548

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Iden- tification 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 regis- tration 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 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.

In the interest of customer satisfaction, dealers should verify that they have the necessary campaign parts in stock, before they schedule an owners vehicle for this service.

If there is evidence of intentional. disablement of the emissi.on system, other than to rectify pulsair leakage, the dealer is to notify the vehicle owner of this condition and ask the owner if he/she wants the system restored. The cost of restoration will be the responsibility of the vehicle owner.

PARTS INFORMATION

Parts required to complete this modification are to be obtained from General Motors Warehousing and Distribution Division (GMWDD). To ensure that these parts will be obtained as soon as possible they should be ordered from GMWDD on a C.I.O. order with no special instruction code, but on an advise code (2).

PART NUMBER DESCRIPTION QUANTITY ----------- ----------- --------- 10045075 Air Bleed Harness Kit 1

10045073 Single Port Pulsair Kit As required

It is recommended that some quantity of Air Bleed Harness Kits and Single Port Pulsair Kits be ordered upon receipt of this bulletin to allow modification of vehicles returned unexpectedly so as to minimize owner inconvenience.

CAMPAIGN SERVICE REQUIREMENTS

STEP 1 Vehicles equipped with the 4 port (blue) pulsair pipe assembly will require its replacement with the single port pulsair kit P/N 10045073. Follow instructions provided on P/N 10045074 instruction sheet included in the kit.

Vehicles equipped with the 4 port (black) stainless steel pulsair pipe assembly DO NOT require the single port pulsair kit.

STEP 2 In addition to Step 1 all vehicles must have an air bleed valve harness kit, P/N 10045075. Follow instructions provided on P/N 10045076 instruction sheet included in the kit.

SERVICE PROCEDURE

STEP I - SINGLE PORT PULSAIR PIPE INSTALLATION KIT. FOLLOW THE INSTRUCTION SHEET P/N 10045074 INCLUDED IN THE KIT.

Replace 4 port (blue) pulsair assembly with a single tube kit assembly (P/N 10045073). (Refer Figure 1). The single tube assembly should be installed by mounting the single tube fitting in the number two (2) cylinder exhaust port. The tube bracket should be attached to the stud (plug) that will be installed in the number one (#I) cylinder exhaust port. Plugs should be installed in exhaust ports #3 and #4. The supplied hose connects the single tube assembly to the pulsair solenoid housing.

STEP 2

All vehicles require the installation of an air bleed valve harness kit P/N 10045075. Follow the instruction sbeet P/N 10045076 included in the kit.

AIR BLEED VALVE INSTALLATION INSTRUCTIONS

1. Remove air cleaner assembly.

2. Cut evaporative purge line about 1/2 inch outboard of fuel line. (See View A, Figure 3).

3. Remove rubber isolator mounted on top of carburetor. Pierce 7/32" dia. hole on rear face of isolator, directly above the "V" shaped projection (See View C, Figure 3). The top of the hole should be coincident with the top edge of the rib on the isolator. Reinstall the isolator on the carburetor torquing screws to 2.8 - 4.0 N.m. (25 - 35 in. lbs.).

4. Cut the EGR signal line about one inch outboard of the heater hose at the rear of the engine (See Veiw B, Figure 3).

5. Assemble the air bleed valve and barness assembly to the engine. (Refer Figure 2). Insert the tee fitting into the evaporative purge line. Press the 90 DEG elbow through the 7/32 inch hole in the carburetor isolator. Insert the "Y" plastic fitting into the EGR signal line. Assure hose from air bleed valve to isolator is dressed tight along side of vacuum break housing as shown.

6. Remove the screw which attaches the choke housing to the main body of the carburetor. Attach clip to the carburetor, using washer P/N 11508426; torque screw to 0.6-1.7 N.m. (5-14 in. lbs.).

7. Inspect the installation, making sure that there are no interference conditions with adjacent components.

8. Install air cleaner assembly.

STEP 3

Reset Ingition Timing

1. Reset the ignition timing from 4 DEG BTDC to 8 DEG BTDC as specified on the tune-up label provided. Follow the instructions for "Set Ignition Timing" Section 6D of Service Manual.

STEP 4

Reset Idle RPM

1. Reset the idle RPM to 700 RPM in drive and follow the instructions on the tune-up label provided P/N 14100986.

STEP 5

Reset Carburetor Vacuum Break

1. Reset the carburetor vacuum break from 0.270 inches to 0.300 inches. The adjustment screw is shown in Section 6C under "automatic choke system" and "vacuum break adjustment."

STEP 6

Install Tune-Up Label (Instruction Sheet P/N 10045076 Sheet 2) - (See Figure 4).

1. Cut the old label diagonally across the specification portion and remove the corner of the label. The label is located on the hood.

2. Replace the specifications portion of the label with the new label provided.

3. Add the Emission hose routing label to the air cleaner.

STEP 7

1. Install "Campaign Identification Label."

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.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

** * Failed Parts Labor Labor Other Repair Performed PC Part No. Allow FC OP Hrs Hrs ---------------- -- -------- ----- -- -- ---- ---

Inspect for 00 V3230 .2 .1 campaign Involvement

Inspect & Install 1 10045075 00 V3231 .6 .1 Air Bleed Harness Kit Only

Inspect & Install 2 10045073 00 V3232 .9 .1 Air Bleed harness Kit & Single Port Pulsair Kit (If required)

*Campaign Administrative Allowance.

**The Parts Allowance should be the sum total of the current GMWDD 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.

Dear Chevrolet Owner:

General Motors has determined that certain 1982 Chevrolet Chevette models equipped with RPO L17 (1.6L L4) engine, automatic transmission and Federal emission system, may have certain deficiencies in the emission control system which may result in increased hydrocarbon (HC) and carbon monoxide (CO) emissions.

The cause may be attributed to internal pulsair pipe corrosion (and even- tual perforation causing an exhaust leak), which may result in increased emissions. Also, the carburetor flow characteristics may shift in the rich direction with mileage, further resulting in increased emissions.

It is recommended that you call your Chevrolet dealer service department to arrange a mutually satisfactory service date to have this modification performed. Your dealer will inspect the pulsair pipe assembly and replace as required. In addition, an air bleed valve harness assembly will be installed on the carburetor and spark timing and carburetor choke vacuum break will be set to new specifications. This service will be performed at no charge to you regardless of your vehicle's age or mileage.

Should your dealer find that your emission system has been intentionally disabled, other than to rectify pulsair leaks, at the time this correction is performed, you will be asked if you wish the system to be restored so that it will function as designed. The cost of such restoration will be your responsibility.

Instructions for making the correction(s) have been sent to your dealer. The labor time to perform this service is approximately one hour. Please allow additional time for your dealer to process your vehicle. As mentioned above, please contact your dealer to arrange a mutually satisfactory service date.

The enclosed Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the inspection to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid Owner Identification Reply Card and returning it to us so that we may update our records. Should your dealer not schedule a service date within a reasonable time, you should contact your nearest Chevrolet Zone Office either in person or by telephone for assistance. For your convenience the locations and telephone numbers of the zone offices have been enclosed with this letter.

If your dealer or Chevrolet zone office are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturers Operation Division (EN-340), United States Environmental Protection Agency, 401 M Street, S.W., Washington, D.C. 20460. To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if this recall work is not accomplished.

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

CHEVROLET ZONE OFFICES

WHEN CALLING FOR ASSISTANCE, PLEASE ASK FOR THE CONSUMER RELATIONS REPRESENTATIVE.

ATLANTA HOUSTON Chevrolet Customer Assistance 13101 N.W. Freeway 30007 Van Dyke Suite 101 Warren, MI 48090 Houston, TX 77040 1-800-222-1020 (713)460-7301 BIRMINGHAM INDIANAPOLIS 3490 Independence Hwy. 6910 N. Shadeland Ave. Homewood AL 35259 Indianapolis, IN 46220 (205)287-5306 (317)269-5031 BOSTON JACKSONVILLE Chevrolet Customer Assistance 6622 Southpoint Dr. S. 30007 Van Dyke Suite 200 Warren,MI 48090 Jacksonville, FL 33216 1-800-222-1020 (904)739-7711 BUFFALO KANSAS CITY 2615 Walden Avenue 10800 Farley Cheektowaga, NY 14225 Suite 100 (716)891-7182 Overland Park, KS 66210 CHARLESTON (913)451 -4380 Chevrolet Customer Assistance LOS ANGELES 30007 Van Dyke 233 Wilshire Blvd. Warren, MI 48090 Suite 800 1-800-222-1020 Santa Monica, CA 90401 CHARLOTTE (213) 393-9356 Chevrolet Customer Assistance LOUISVILLE 30007 Van Dyke 9100 Shelbyville Rd. Warren, MI 48090 Paragon Place, Suite 200 1-800-222-1020 Louisville, KY 40222 CHICAGO (502)423-5858 475 Alexis R. Shuman Blvd. MEMPHIS Naperville, IL 60566 866 Ridgeway Loop Ave. (312)961-6380 Memphis, TN 38117 CINCINNATI (901)756-3360 Chevrolet Customer Assistance MILWAUKEE 30007 Van Dyke 333 Bishops Way Warren, MI 48090 Brookfield, WI 53005 1-800-222-1020 (414) 784-2578 CLEVELAND MINNEAPOLIS 25000 Great Northern Corporate Center 7600 Metro Blvd. Suite 444 Edina, MN 55435 North Almsted, OH 44070 (612) 830-4044 (216)265-5600 NEW ORLEANS DALLAS 35451 1-10 Service Road 130 E. Carpenter Freeway Metairie, LA 70002 Irving, TX 75062 (504) 888-9013 (214)659-5441 NORTH JERSEY DENVER 9 Sylvan Way 5460 S. Quebec St. Parsippany, NJ 07054 Suite 330 (201)993-4155 Englewood, CO 80111 OAKLAND (303)930-5720 39465 Paseo Padre Parkway DETROIT Fremont, CA 94538 Chevrolet Customer Assistance (415)498-5080 30007 Van Dyke OKLAHOMA CITY Warren,MI 48090 6307 Waterford Blvd. 1-800-222-1020 Suite 200 FARGO Oklahoma City, OK 73118 1111 38th St.So. (405)841-5000 Fargo, ND 58103 OMAHA (701)282-4451 10836 Old Mill Rd. Omaha, NE 68154 (402) 399-5515

PEORIA 3425 N. Dries Lane Peoria, IL61604 (309)688-1021 PHILADELPHIA 851 Duportail Rd. Wayne, PA 19087 (215) 296-6600 PHOENIX 1625 W. Fountainhead Pky. Tempe, AZ 85282 (602) 829-6201 PITTSBURGH 2 Penn Center W. Suite 200 Pittsburgh, PA 15276 (412)928-5125 PORTLAND 10300 S.W. Greenburg Road, Suite 500 Portland, OR 97223 (503)293-5000 RICHMOND Chevrolet Customer Assistance 30007 Van Dyke Warren, MI 48090 1-800-222-1020 SALT LAKE CITY 303 East South Temple Salt Lake City, UT 84111 (801) 534-7125 ST. LOUIS 83 Progress Parkway Maryland Heights, MO 63043 (314) 895-8608/8609 SYRACUSE Chevrolet Customer Assistance 30007 Van Dyke Warren MI 48090 1-800-222-1020 TARRYTOWN 2500 Westchester Ave. Purchase, NY 10577 (914)251-5121 WASHINGTON 1395 Piccard Drive Rockville, MD 20850 (301) 258-1444 CENTRAL OFFICES UNITED STATES Chevrolet Motor Division Consumer Relations Dept. Chevrolet Central Office Warren, Michigan 48090 (313) 492-5500 CANADA Customer Services Department General Motors of Canada Limited Oshawa, Ontario L1J 5Z6 (416) 644-6624

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.