A/C EVAPORATOR CORE PIPE TO VACUUM PIPE INTERFERENCE

SOME EARLY PRODUCTION 1981 OMEGA MODELS EQUIPPED WITH AIR CONDITIONING AND 2.5 LITER L4 ENGINE MAY EXPERIENCE AN INTERFERENCE BETWEEN THE ALUMINUM A/C EVAPORATOR CORE TO ACCUMULATOR PIPE AND AN ADJACENT STEEL VACUUM SUPPLY PIPE. THE RELATIVE MOTION BETWEEN THESE TWO PIPES MAY RESULT IN LOCALIZED WEAR OF THE A/C EVAPORATOR PIPE AND POSSIBLE DISCHARGE OF THE AIR CONDITIONING SYSTEM.

IF THIS CONDITION IS NOTED, IT SHOULD BE CORRECTED AS FOLLOWS:

INTERFERENCE WEAR BUT NO A/C DISCHARGE - USE PROCEDURE 1 INTERFERENCE WEAR THROUGH WITH A/C DISCHARGE - USE PROCEDURE 11

PROCEDURE 1

INSTALL PIPE KIT, PART NUMBER 10023092 AS FOLLOWS:

1. RAISE HOOD AND COVER FENDERS. 2. REMOVE VACUUM PIPE AND HOSES (S) ASSEMBLY (CLAMPS A,C, AND E; HOSES B AND F; PIPE D)(FIG. 1). 3. RETAIN HOSE B AND CLAMPS A,C, AND E FOR REINSTALLATION. DISCARD HOSE F AND PIPE D.

4. PREASSEMBLE PIPE AND HOSE(S) ASSEMBLY AS SHOWN IN FIG. 2 USE PREVIOUSLY REMOVED HOSE B AND CLAMPS A,C, AND E WITH REPAIR KIT VACUUM PIPE AND REPAIR KIT VACUUM HOSE.

LAY PARTS ON A FLAT WORK SURFACE AND PREASSEMBLE AS SHOWN IN FIG. 2. INSTALL REPAIR KIT PLASTIC CONDUIT OVER VACUUM PIPE. INSTALL ASSEMBLY AS SHOWN IN FIG. 3. CLAMP A SHOULD BE SLID UP HOSE B DURING PRE- ASSEMBLY, THEN SLID DOWN TO PROPER POSITION AFTER INSTALLATION ON CAR AS SHOWN IN FIG. 3. REPAIR KIT PARTS ARE DENOTED BY AN ASTERISK * IN FIGS. 2 & 3. 5. LUBRICATE HOSE ENDS OF VACUUM PIPE AND VACUUM HOSE(S) ASSEMBLY AND INSTALL AS SHOWN IN FIG. 3. POSITION TANGS ON CLAMP E TOWARDS FRONT OF CAR. 6. INSTALL REPAIR KIT CLAMP (LARGE, PLATED) AROUND VACUUM HOSE AND INSTALL REPAIR KIT CLAMP (SMALL, COATED) AROUND A/C LIQUID LINE. SEE DETAIL, FIG. 3, VIEW III. INSTALL SCREW THROUGH BOTH CLAMPS AND SECURE NUT ON UNDERSIDE. TORQUE TO 6 N.M. (55 IN.LBS.). 7. REMOVE FENDER COVERS AND CLOSE HOOD. PROCEDURE II

1. RAISE HOOD AND COVER FENDERS.

2. IF A/C SYSTEM HAS BEEN DISCHARGED BECAUSE OF A WORN THROUGH A/C EVAPORATOR PIPE, THE PIPE MAY BE REPAIRED BY WELDING OR SOLDERING. PROCEED TO (A).

A. ASSURE THAT A/C SYSTEM HAS BEEN COMPLETELY DISCHARGED. B. LOOSEN, BUT DO NOT REMOVE, ACCUMULATOR/DRYER CLAMP SCREW. DISCONNECT EVAPORATOR CORE PIPE TO ACCUMULATOR A/C FITTING, REMOVE "O" RING AND RECONNECT FITTING FINGER TIGHT. C. NOTICE: CAREFULLY COVER CARBURETOR AIR HORN AREA AND SEAL WITH MASK- ING TAPE. PROTECT ADJACENT COMPONENTS, IDLE SPEED MOTOR, HIGH BLOWER RELAY, WIPER MOTOR, COWL, ETC.) WITH FIRE RESISTANT MATERIAL TO PROTECT FROM HEAT GENERATED BY WELDING OR SOLDERING OPERATION. D. WELD OR SOLDER REPAIR DAMAGED AREA USING AVAILABLE COMMERCIALLY ACCEPTABLE ALUMINUM (HELIARC OR GAS) WELDING OR SOLDERING TECH- NIQUES AND GOOD WELDING SHOP PRACTICE. CLEAN WELD AREA THOROUGHLY AFTER WELDING TO REMOVE FLUX AND RESIDUE (GAS WELD ONLY).

SUGGESTED WELDING OR SOLDERING MATERIALS:

HELIARC WELDING - ER1100, ER4043 OR EQUIVALENT ALUMINUM WIRE.

GAS WELDING - ER1100, ER4043 OR EQUIVALENT ALUMINUM ROD WITH EUTECTIC 21X, CROWN NO. 100, OXWELD OR EQUIVALENT FLUX.

CROWN NO. 90, EUTECTIC 21, WELCO 120 OR EQUIVALENT ALUMINUM ROD WITH EUTECTIC 21X, CROWN NO. 100, OXWELD OR EQUIVALENT FLUX.

FLUX CORED ALUMINUM ROD - CROWN 110, EUTECTIC 21FC OR EQUIVALENT.

FLUX COATED ALUMINUM ROD - CROWN 300, EUTACTIC 2101 OR EQUIVALENT.

FLUXLESS SOLDER NEY 380, 3/32" DIAMTER SOLDER ROD OR EQUIVALENT. MANUFACTURER INSTRUCTIONS MUST BE FOLLOWED CAREFULLY TO MAKE A GOOD REPAIR.

E. REMOVE HEAT PROTECTION COVERING AND ALLOW WALD TO COOL.

F. DISCONNECT A/C FITTING, AND THEN RECONNECT FITTING USING A NEW "O" RING (REMOVED IN STEP B.) LUBRICATED WITH 525 VISCOSITY REFRIGERANT OIL. TIGHTEN CONNECTION TO 29-37 N.M (21-27 FT.LBS.) TIGHTEN ACCUMULATOR/DRYER CLAMP SCREW SECURELY.

G. EVACUATE AND RECHARGE SYSTEM (1981 OMEGA SERVICE MANUAL, SECTION 1B)

H. LEAK TEST REPAIRED AREA AND EVAPORATOR CORE PIPE TO ACCUMULATOR CONNECTION.

I. IF LEAK IS DETECTED AT WELD REPAIR AREA, EVAPORATOR CORE MUST BE REPLACED.

3. CORRECT VACUUM PIPE TO A/C EVAPORATOR PIPE INTERFERENCE CONDITION BY INSTALLING REPAIR KIT, PART NUMBER 10023092 PER PROCEDURE 1 IN THIS BULLETIN.

PRODUCTION CHANGE

THE INTERFERENCE CONDITION HAS BEEN CORRECTED IN PRODUCTION BY THE INSTAL- LATION OF A PROTECTIVE SLEEVE OVER THE VACUUM PIPE. VEHICLES PRODUCED AFTE THE VIN BREAKPOINT LISTED BELOW SHOULD HAVE THE PROTECTIVE SLEEVE INSTALLED AND WILL NOT REQUIRE THE SERVICE PROCEDURE(S).

ASSEMBLY PLANT VIN WILLOW RUN BW131719

WARRANTY INFORMATION

LABOR FAILURE LABOR OPERATION CODE HOURS

1. T0050 92 0.3 HOUR 2. T0052 92 1.0 HOUR 3. T0051 92 0.7 HOUR

DESCRIPTION:

1. INSTALL PIPE KIT. 2. INSTALL PIPE KIT, INSTALL NEW "O" RING, DEALER "WELD REPAIR" OF EVAPORATOR CORE PIPE, AND CHARGE SYSTEM. 3. INSTALL PIPE KIT, INSTALL NEW "O" RING, SUBLET "WELD REPAIR" OF EVAPORATOR CORE PIPE, AND CHARGE SYSTEM.

USE ONLY ONE OF THE LABOR OPERATIONS LISTED

PARTS:

DEALERS SHOULD ORDER PART NUMBER 10023092, PIPE KIT. THIS KIT INCLUDES THE FOLLOWING MATERIALS: PLASTIC CONDUIT, VACUUM PIPE, VACUUM HOSE, CLAMP ILARGE, PLATED), CLAMP (SMALL, COATED), SCREW AND NUT.

PARTS REQUIRED ARE TO BE LISTED ON YOUR WARRANTY CLAIM IN THE NORMAL MANNER. PARTS WILL BE CREDITED AT DEALER NET, PLUS 30% DEALER HANDLING ALLOWANCE. IF RECHARGING THE A/C SYSTEM IS NECESSARY, A DEALER ALLOWANCE OF $8.32 WHICH INCLUDES THE 30% MARKUP, MAY BE LISTED UNDER THE PARTS ALLOWANCE COLUMN RE- LATIVE TO LABOR OPERATIONS 2 OR 3. THIS INCLUDES 44 OZ. OF FREON.

IF DEALER SUBLETS WELD REPAIR, LABOR OPERATION 3 MUST BE LISTED, AND THE SUBLET REPAIR AMOUNT ENTERED UNDER THE SULET DEALER MATERIAL TOWING COLUMN.

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.