CAMPAIGN: PUSH-PULL HEADLIGHT SWITCH DEFECTIVE. Chevrolet Chevette 1986

For 1990-2009 cars

# CAMPAIGN: PUSH-PULL HEADLIGHT SWITCH DEFECTIVE

#### Model and Year: 1986 CHEVROLET PASSENGER CARS, MEDIUM DUTY TRUCKS AND 1985-1986 LIGHT DUTY TRUCKS

THIS BULLETIN IS BEING REISSUED TO SUPERSEDE PRODUCT CAMPAIGN BULLETIN 86CO5 DATED MAY, 1986. UPON RECEIPT OF THE REISSUED BULLETIN 86CO5(a) DESTROY 86CO5.

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 owners 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 mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

#### CONDITION

General Motors has determined that a defect which relates to motor vehicle safety exists in some 1986 Chevrolet Passenger Cars, Medium Duty Trucks and 1985-1986 Light Duty Trucks. The push-pull headlight switch might have been manufactured with electrical contacts which could potentially result in an intermittent headlight circuit. An intermittent circuit could cause the headlights to suddenly go out. Sudden loss of the head-lights under severe weather or nighttime driving conditions could reduce driver visibility which might result in a vehicle crash without prior warning.

#### DEALER ACTION

To prevent this condition dealers are required to inspect, and if neces- sary, replace push-pull headlight switches on suspect vehicles per the Vehicles Involved and Service Procedure sections of this bulletin.

#### VEHICLES INVOLVED

Certain 1986 Chevrolet Passenger Cars, Medium Duty and 1985-1986 Light Duty Trucks within the following parameters:

YEAR PLANT FROM THROUGH ---- ----- ---- --------

"S/T" LIGHT DUTY TRUCKS ---------------------- 1985 Pontiac F0213991 F0217303 1985 Moraine F2261445 F2266283

"P" FWD. CONTROL TRUCKS ----------------------- 1985 Detroit F3345668 F3346279 # 1986 Detroit G3315972 G3317552

#### CELEBRITY

1986 Oklahoma City G6117716 G6121696 # G6222460 G6230910 1986 Oshawa G1126879 G1127808 # G1227276 G1237184 1986 Framingham GGIO4644 GG104779 # GG131917 GG135586

#### CAMARO

1986 Van Nuys GLI08269 GLI11008 # CLI69838 GLI71816 Norwood GN112086 GN115431 # GN149765 GN165774

#### MONTE CARLO

1986 Arlington CRI12552 GRI16439 # CRI74982 GRI79215

#### CAVALIER (EXCEPT JE & JF SERIES)

1986 Leeds GK110420 GK112653 # GK145880 GKI48445 1986 Lordstown G7119205 G7124854 # C7204309 G7208597 1986 Janesville GJII9727 GJI30584 # GJ212326 GJ239084

#### CHEVETTE

1986 Lakewood GA115292 GA117670 # GA175188 CA178124

#### CORVETTE

1986 Bowling Green G5108246 C5108469

#### MEDIUM DUTY (CONVENTIONAL)

1986 Pontiac GVIO2035 GVIO7076

#### MEDIUM DUTY (P6TO42)

1986 Pontiac GV106812 CV106880

#### MEDIUM DUTY (B6PO42 SCHOOL BUS)

1986 Pontiac GVIO6353 CV107074

"C/K" LIGHT DUTY TRUCKS ---------------------- 1986 Janesville GJII3536 GJII5892 # GJI55888 GJI59088 1986 St. Louis GS114175 GS116322 # GS163672 GS168176 1986 Oshawa #2 G1115519 C1117574 # G1177130 C1183207 1986 Flint #1 GF318360 CF319976 # CF388768 GF393843 1986 Flint #2 GF113688 CF114911 # GF167051 CF170532

'G' VAN ------ 1986 Lordstown G7103939 C7105085 # G7163429 G7166183 1986 Scarborough G4110625 G4113044 # G4148711 C4151868

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 Lith the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

# Denotes Change

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 has no 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 modification according to instructions contained in this bulletin.

#### PARTS INFORMATION

The following push-pull headlight switches will be required, if inspection indicates replacement is necessary.

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).

#### MODEL PART NUMBER QUANTITY ----- ----------- -------- Celebrity, Monte Carlo, 1995217 1 Per Vehicle Cavalier, Chevette & "S/T" Trucks

Camaro 1995226 1 Per Vehicle

Corvette 1995257 1 Per Vehicle

"C/K" Light Duty 1995216 1 Per Vehicle Trucks, "G" Vans and "P" Fwd Control

Medium Duty 1995194 1 Per Vehicle Conventional, P6TO42 & School Bus

#### SERVICE PROCEDURE

# NOTE: EACH SUSPECT PUSH-PULL HEADLIGHT SWITCH MUST BE INSPECTED. THERE ARE TWO DIFFERENT INSPECTION PROCEDURES DEPENDING ON SUSPECT DATE PERIOD OF SWITCH. ONE REQUIRES INSPECTION OF A "DATE CODE"; THE OTHER A "CAVITY CODE." IF THE SWITCH IS NOT WITHIN THE SUSPECT DATE CODES, OR CAVITY CODES, IT NEED NOT BE REPLACED. SEE INSPECTION PROCEDURE.

I. Headlamp Switch Removal. Refer to appropriate passenger car or truck Service Manual.

- 1985 S/T Light Duty Truck - "1985 S-10 Light Duty Truck Shop Manual" (ST-369-85) page 8B-16.

- 1985 "P" Fwd Control - "1985 10-30 Series Light Duty Truck Shop Manual" (ST-330-85) page 8B-16. Follow the procedure for "G" Series Trucks.

- 1986 Monte Carlo - "1986 Caprice, Monte Cv"rlo, El Camino Service Manual" (ST-384-86) page 8B-18.

- 1986 Camaro - "1986 Camaro Service Manual" (ST-386-86) page 8B-17.

- 1986 Cavalier - "1986 Cavalier Shop Manual" (ST-366-86) page 8C-2.

- 1986 Celebrity - "1986 Celebrity Shop Manual" (ST-365-86) page 8C-3.

- 1986 Chevette - "1986 Chevette Shop Manual" (ST-357-86) page 8B-16

- 1986 "C, K, G" Light Duty Trucks - "1986 10-30 Series Light Duty # Truck Shop Manual" (ST-330-86) page 8B-24. 1986 "P" Fwd. Control Follow the procedure for "G" series trucks.

- 1986 Medium Duty Trucks - "1986 Medium Duty Trucks Service Manual" (ST-331-84) page 8C-4.

# Denotes Change

- 1986 Corvette - The 1986 Corvette Shop Manual provides very limited information on headlamp switch replacement. We have, therefore, provided a removal procedure that can be used.

a) Disconnect battery ground cable.

b) Remove light switch knob (spring loaded) and steering wheel tilt lever.

c) Remove cluster bezel from I.P.

d) Remove light switch nut.

e) Remove fuse panel cover and I.P. right side trim plate.

f) Remove I.P. pad.

g) Disconnect electrical connector from headlamp switch.

h) Refer to Section II for inspection and reinstallation procedure.

# VEHICLES IDENTIFTED BY A (#) SIGN IN THE "VEHICLES INVOLVED" SECTION SHOULD REFER TO SECTION III FOR "CAVITY CODE" INSPECTION/ REINSTALLATION INSTRUCTIONS. ALL OTHER VEHICLES USE THE "DATE CODE" INSPECTION/REINSTALLATION INSTRUCTIONS IN SECTION II.

# II. "DATE CODE" INSPECTION PROCEDURE AND REINSTALLATION OF HEADLAMP SWITCH.

1. After removing the Headlight Switch from the Instrument Panel, refer to Figure 1 to locate and identify the date code.

2. The four digit date code will appear the same on any switch regardless of the model usage or part number.

3. If the date code is 0015 or between the range 9235 through 9305,replace the switch using the correct part number per the Parts Information section.

If the switch is not within the suspect date codes, reconnect the existing switch. Proceed to step 4.

4. Reassemble the Headlight Switch and I/P Trimplate per the applicable Service Information Manual instructions.

5. Install the Campaign Identification Label.

# Denotes Change

# III. "CAVITY CODE" INSPECTION PROCEDURE AND-REINSTALLATION OF HEADLAMP SWITCH.

1. After removing the headlight switch from the Instrument Panel (I.P.), refer to Figure 2 to locate and identify the cavity code.

2. The alphabetical cavity cade will appear in the same area on any switch regardless of the model usage or part number.

3. If the cavity code is a "D" or "M", replace the switch using the correct part number per the Parts Information section.

If the switch does not have the suspect alphabetical eavity codes, reconnect the existing switch. Proceed to step 4.

4. Reassemble the headlight switch and I.P. trimplate per the applicable Service Information Manual instructions.

5. Install the 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 ballpaint 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 LAB OTH REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS -------------------------------------------------------------------------- # INSPECT HEADLIGHT SWITCH 1986 CHEVETTE, "C", "K" & M.D. TRUCK 00 V3260 .3 .1 ---------------------------------------------------------------------------- # INSPECT HEADLIGHT SWTICH 1986 MONTE CARLO, "G" VAN & 1985-86 "P" FWD CONTROL MODELS 0 V3262 .4 .1 ---------------------------------------------------------------------------- INSPECT HEADLIGHT SWITCH 1986 CELEBRITY & CAVALIER MODELS 00 V3266 .5 .1 ---------------------------------------------------------------------------- INSPECT HEADLIGHT SWITCH 1986 CAMARO MODELS 0 V3267 .6 .1 ---------------------------------------------------------------------------- INSPECT HEADLIGHT SWITCH 1986 CORVETTE MODELS 00 V3268 .7 .1 ---------------------------------------------------------------------------- # INSPECT HEADLIGHT SWITCH 1985 "S/T" TRUCK MODELS 00 V3269 .9 .1 ---------------------------------------------------------------------------- # INSPECT AND REPLACE 1995217 HEADLIGHT SWITCH 1995216 1986 CHEVETTE, "C", "K" & M.D. TRUCK 1995194 ** 00 V3350 .3 .1 ---------------------------------------------------------------------------- # INSPECT AND REPLACE HEADLIGHT SWITCH 1986 MONTE CARLO "G" VAN & 1985-86 1995217 "P" FWD CONTROL MODELS 1995216 ** 00 V3351 .4 .1 ---------------------------------------------------------------------------- INSPECT AND REPLACE HEADLIGHT SWITCH 1986 CELEBRITY & CAVALIER MODELS 1995217 ** 00 V3352 .5 .1 ---------------------------------------------------------------------------- INSPECT AND REPLACE HEADLIGHT SWITCH 1986 CAMARO MODELS 1995226 ** 00 V3353 .6 .1 ---------------------------------------------------------------------------- INSPECT AND REPLACE HEADLIGHT SWITCH 1986 CORVETTE MODELS 1995257 ** 00 V3354 .7 .1 ---------------------------------------------------------------------------- # INSPECT AND REPLACE HEADLIGHT SWITCH 1985 "S/T" TRUCK MODELS 1995217 ** 00 V3355 .9 .1 ----------------------------------------------------------------------------

*Campaign Administrative Allowance.

**The Parts Allowance should be the sum total of the current GMWDD Dealer Net plus 30% of all parts required for the repair.

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

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

# DENOTES CHANGE

(Notification Used By Chevrolet Motor Division)

Dear Chevrolet Owner:

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

General Motors has determined that a defect which relates to motor vehicle safety exists in some 1986 Chevrolet Passenger Cars and Medium Duty Trucks and 1985-1986 Light Duty Trucks. The push-pull headlight switch might have been manufactured with electrical contacts which allow an intermittent headlight circuit. An intermittent circuit could cause the headlights to flicker or suddenly go out. Sudden loss of the headlights under severe weather or nighttime driving conditions could reduce driver visibility which might result in a vehicle crash without prior warning.

Until you have had an opportunity to have your Chevrolet corrected, you should be alert for signs of an intermittent headlight circuit. For example, you might experience flickering headlights or temporary delay when you pull the headlight switch "ON."

To prevent this condition from occurring, please contact your Chevrolet dealer on or after the date shown below to arrange a service date to have your Chevrolet inspected. Your dealer will check the headlight switch. If necessary, the switch will be replaced. This service will be completed at no charge to you.

Instructions have been sent to your Chevrolet dealer. It is estimated that parts will be available October 1, 1986. The labor time to check the headlight switch and replace it, if necessary, is about 35 minutes. Please ask your dealer if you wish to know how much additional time will be needed to process your vehicle.

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 Warranty and Owner Assistance Information Booklet which is in your glove compartment.

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 and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh St., 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 Chevrolet. Presentation of this card to your dealer will assist in making the inspection and correction in the shortest possible time. If you have sold or traded your vehicle, please complete the postage-paid card and return it to us. This will assist us in assuring all affected vehicles have been corrected.

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

Chevrolet Motor Division GENERAL MOTORS CORPORATION

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.