CAMPAIGN: EXH.SYS. CORROSION (WHERE FREQ. DRIVEN ON SALT). Geo Tracker - 2WD 1991

For 1990-2009 cars

# CAMPAIGN: EXH.SYS. CORROSION (WHERE FREQ. DRIVEN ON SALT)

#### Subject: PRODUCT CAMPAIGN 91C29 - EXHAUST SYSTEM CORROSION

#### Model and Year: 1989-91 GEO TRACKER

#### To: All Chevrolet/Geo Dealers

General Motors has determined that certain 1989-91 Geo Trackers may experience a perforation of the two-piece muffler/tailpipe due to corrosion if the vehicle is frequently driven on roads where large amounts of salt are applied during winter weather. Continuing corrosion of a perforated tailpipe can eventually result in the tailpipe becoming completely separated from the rest of the exhaust system. Exhaust gas leakage from a separated tailpipe can cause heat damage to the vehicle's rear floor material and carpeting.

To prevent this condition from occurring, dealers are to install an exhaust heat shield on involved vehicles.

#### INVOLVED VEHICLES

Involved are all vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1989 Tracker Iwata "W" KW825033 KW835059

1990 Tracker CAMI "6" L6200057 L6235055

1991 Tracker CAMI "6" M6900005 M6914144

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 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 has no involved 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 correction according to instructions contained in this bulletin.

#### PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Quantity/ Part Number Description Vehicle ----------- ----------- 96067161 Exhaust Heat Shield Kit 1

Each Kit Contains: 1 Heat Shield Panel 4 Heat Shield Panel Screws 1 Hose/Wire Cover 1 Cover Clamp 1 Cover/Frame Clamp 1 Exhaust Pipe Loop 2 Exhaust Pipe Loop Bolts

#### NOTICE: KITS ARE ONLY AVAILABLE IN MERCHANDISED SETS OF 5.

#### SPECIAL TOOLS

Each dealer will be shipped a 20.511 long punch tool (No Tool Number) for this campaign at no charge to dealers. The tool is being sent to dealers at the same time this bulletin is being mailed, but is being shipped separate from the bulletin. Additional or replacement tools can be obtained from DAC.

SERVICE PROCEDURE - (Numbers in () refer to illustrations on page 4)

1. Ensure vehicle floor is clean and dry in area where heat shield is to be installed (see illustrations).

2. Raise vehicle on hoist.

3. Install hose/wire cover (3) over evaporative hose of fuel tank and over wiring harness using cover clamp (4) and cover/frame clamp (5) (see "Bottom View" illustration).

4. Position heat shield panel (1) to floor pan so embossment on heat shield panel is aligned with #1 body hole. Panel-to-side frame clearance is approximately 15 mm and panel-to-crossmember clearance is approximately 10 mm (see illustrations on page 4).

5. Punch a 4 mm (5/32") hole into floor panel at each of four corner anchor holes of heat shield panel using the 20.5" long punch tool supplied for this campaign. Tap punch tool several times with hammer until shoulder of punching tool contacts floor panel.

6. Apply small amount of anti-corrosive sealer (such as GM 12345489) to threads of each heat shield screw (7) and install heat shield panel using four screws.

7. Install exhaust pipe loop (2) on heat shield panel using two exhaust pipe loop bolts (6).

8. Lower vehicle.

9. Install Campaign Identification Label.

#### CAMPAIGN LABEL

Each vehicle corrected 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 campaign number and the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point 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. Additional "Campaign Identification Labels" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW 0P HRS HRS ------------------------------------------------------------------------- Install Heat Shield 1 96067161 ** SK-00 V7330 0.4 0.1

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO 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 Geo Tracker Owner:

This notice is sent to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

REASON FOR THIS RECALL

General Motors has determined that certain 1989-91 Geo Trackers may experience a perforation of the two-piece muffler/tailpipe due to corrosion if the vehicle is frequently driven on roads where large amounts of salt are applied during winter weather. Continuing corrosion of a perforated tailpipe can eventually result in the tailpipe becoming completely separated from the rest of the exhaust system. Exhaust gas leakage from a separated tailpipe can cause heat damage to the vehicle's rear floor material and carpeting.

WHAT WE WILL DO

To prevent this condition from occurring, your dealer will install an exhaust heat shield to your vehicle. This service will be performed for you at no charge. WHAT YOU SHOULD DO

Please contact your Chevrolet/Geo dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

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

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.