For 1990-2009 cars

# CAMPAIGN: BATTERY LEAKAGE- REPLACE HEAVY DUTY BATTERY

#### Models/Years 1985 NINETY-EIGHTS EQUIPPED WITH 107 BATTERY

General Motors has determined that some 1985 Ninety-Eight Coupes and Sedans were assembled with batteries that may leak acid. This acid may cause possible degradation of the transmission cooler hoses on gasoline engine equipped vehicles and other components in the area of the battery on all vehicles.

To prevent these conditions from occurring on vehicles involved, dealers are to determine if the vehicle is equipped with original equipment battery number 107 or aftermarket number 78A-60. If the vehicle is equipped with one of these batteries, they will be replaced with a new 78A-72 battery, the transmission cooler hoses on gasoline engine equipped vehicles will be replaced, and any other battery acid affected component will be cleaned or replaced.

#### VEHICLES INVOLVED

Certain 1985 Ninety-Eight Coupes and Sedans with 3.0L and 3.8L gasoline engines and 4.3L diesel engines and 107 or 78A-60 batteries within the following VIN breakpoints:

PLANT FROM TO AND INCLUDING ----- ---- ---------------- Wentzville F1300076 F1314724 Orion F4300078 F4314377

SOME OF THESE VEHICLES WITHIN THESE BREAKPOINTS WILL NOT REQUIRE BATTERY REPLACEMENT AS THEY WERE NOT ASSEMBLED WITH A 107 BATTERY.

#### DEALER ACTION

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 in this builetin.

#### SERVICE PROCEDURE

PART A - INSPECTION OF BATTERY

1. Open vehicle hood, cover fenders, and inspect "Caution" label on top surface of battery. Refer to Figure 1.

a. Replace batteries identified as original equipment number "107" or aftermarket (replacement) number "78A-60" on "Caution" label following the complete procedure in PART B of this procedure.

b. DO NOT replace batteries that ARE NOT identified as described in Step "a" above, as no further action is required, except to install a campaign identification label, Step 10 of PART B of this procedure.

PART B - COMPONENT INSPECTION, CLEANING, REPAIR AND REPLACEMENT

#### CAUTION:

Follow recommended precautions in handling batteries and potential battery acid contamination components. Battery acid is corrosive. Proper protective clothing and safety glasses should be worn during the following work:

1. Disconnect battery negative cable, positive cable, remove retainer screw and retainer. Carefully remove battery, tag with vehicle information, and store in a safe area for disposition.

2. Inspect the following areas for evidence of battery acid. Make note of areas where acid or acid residue can usually be identified as a whitish discoloration or deposit. Acid can result in corrosion of paint peeling on metals and softening and blistering of rubber and certain plastic compounds.

a. Battery tray, hold-down bolt, and plastic clamp, b. Left inner fender area, (right inner fender area if diesel engine), c. Left shock tower, d. Left horns, e. Radiator, (air conditioning line, muffler hose, etc. diesel engine only), f. Lower radiator support, g. Transmission oil cooler lines, hoses, and clamps, (gasoline only), h. Power steering oil cooler lines, hold-down bracket and bolt, i. Hood release cable, j. Windshield washer hose, k. Upper radiator hose and clamp at radiator, 1. Air cleaner housing and iniet area (3.8L engine only), m. Hood insulation above battery, n. Engine cradle under battery, o. Side rail under battery, p. Any other suspected contaminated part in battery area. q. Engine oil cooler pipes (diesel engine only).

3. If here were no evidence of battery acid found in Step 2, proceed to Step 5 of this procedure to replace transmission cooler hoses (on gasoline engine vehicles only) and install new battery. If evidence of acid presence was noted in Step 3, clean affected parts and areas using the following procedure:

a. Purchase sodium bicarbonate (baking soda) locally. b. Sprinkle affected area with baking soda. c. Mix a solution of one (1) part baking soda by volume to one (1) part water. d. Brush affected parts and areas liberally with solution, making sure to cover all surfaces. e. Let stand until affected area stops gassing (foaming). f. Rinse with clean water. g. Repeat application five (5) times and rinse.

4. After neutralizing acid in Step 3, proceed to correct ponible degradation, as listed below. Perform only the appropriate steps listed where acid presence was noted:

STANDARD PAINT REFINISH PROCEDURES SHOULD BE USED WHEN REPAIRING PAINT THAT WAS DAMAGED BY BATTERY ACID.

a. Power Steering Oil Cooler Lines (Gasoline Engine Only)

Place container under line connections. Remove old lines. Clean hold-down bracket, attaching screw, lower radiator support behind hold-down bracket and along side rail where lines were, with baking soda and water solution. Replace power steering oil cooler line with package number 22527846. Refer to Figure 2. Fill power steering system to replace lost fluid.

b. Battery Tray, Hold-down Bolt and Plastic Clamp

Make sure acid residue has been thoroughly cleaned. Repaint tray as required.

c. Lower Radiator Support and Radiator

Make sure acid residue has been thoroughly cleaned. Repaint affected areas as required.

d. Upper Radiator Hose and Clamp at Radiator (Lower Hose on Diesel)

Remove hose and replace clamp at radiator. Install new hose and clamp at radiator. Fill radiator with recommended coolant. Tighten clamps to 2 N - m (18 lbs. in.).

e. Windshield Washer Container Hose and Hood Release Cable (Gasoline Engine Only.

Replace washer container hose with service part number 1359744 cut to proper length. Replace hood release cable.

f. Other Parts and Areas

Work performed and time allowance in the following areas must have zone approval.

1) Left or right fender area, 2) Left or right shock tower, 3) Horns, 4) Air cleaner housing and inlet area, 5) Hood insulation above battery, if battery acid is evidenced on hood insulator, it should be replaced and inner hood panel should be cleaned and paint repaired, if required. 6) Engine cradle under battery, 7) Other suspected contaminated parts in battery area.

5. Place drain container under transmission cooler hoses (gasoline engine only).

6. Remove transmission cooler hoses (gasoline engine only). If required, clean end of lines with a clean rag soaked in the baking soda and water solution; cover ends of lines with tape and repaint affected areas. Remove tape. Install new hoses and clamps using parts in package 25526686. Refer to Figure 3. Tighten clamps to 1.5 N - m (13 lbs. in.).

7. Measure transmission oil lost during hose replacement and install same amount of new oil in transmission.

8. Install new service battery 78A-72, part number 1981590. Tighten battery retainer screw to 17 N-m (13 lbs. ft.). Connect positive cable, negative cable, and tighten cable bolts to 12N-m (9 lbs. ft.).

9. Start engine and check for leaks at cooler hose connections, and at connections of other replaced fluid lines and hoses. Repair, if required.

10. Install a Campaign Identification label. Each vehicle modified in instructions outlined in this procedure will require a Campaign Identification label. Each label provides a space to include the campaign number, the five (5) digit dealer code of the dealer performing the campaign service, and the date the campaign was performed. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the radiator upper mounting support and apply the campaign label where it is readily visible.

#### PARTS INFORMATION

The batteries for this campaign are to be obtained from your local AC-Delco outiet. One 78A-72, part number 1981590, is required for each vehicle that requires a battery replacement. The other parts for this campaign are to be obtained from WDDGM as follows:

Description Part No. Number Per Vehicle ----------- --------- ------------------ Kit, Transmission Cooler - Upper 25526686 1 for each vehicle and Lower Hoses & Clamps with 107 or 78A-60 battery and equipped with a gasoline engine

Hood Release Cable 20470537 As Required (Gas Engine Only) Power Steering Cooler 22527846 As Required Pipe Package (Gas Engine Only) Washer Hose 5/32" 1359744 As Required (25 Ft. Roll)

Upper Radiator Hose 3.8L Engine 25516661 As Required 3.0L Engine 25515308 As Required

Lower Radiator Hose 4.3L Diesel 22525351 As Required

FOR ADDITIONAL PARTS THAT MAY BE REQUIRED, REFER TO THE 1985 OLDSMOBILE "C" CAR PARTS AND ILLUSTRATION CATALOG.

To ensure that parts will be obtained as soon as possible, they should be ordered from WDDGM on a C.I.O. order with NO special instruction code, but order on an advise code (2).

All replaced parts, must be held for disposition by Oldsmobile service personnel.

#### SPECIAL MATERIALS

Sodium bircarbonate (baking soda) is required for cleaning acid affected parts and paint, should be purchased locally.

#### WARRANTY INFORMATION

Failure Operation Labor Operation Code No. Hours ---------- ---- ---- ------ Inspect Battery Only 96 V2660 .2

Inspect, Replace Battery 96 V2665 .3 (Diesel Engines Only)

Inspect, Replace Battery and 96 V2661 .5 Replace Transmission Cooler Hoses (Gas Engines Only)

Add the following operations and labor times to operation number V2665 or V2661, if required.

Replace Power Steering Cooler Pipe (Gas Engine Only) .4 Replace Washer Hose .1 Replace Radiator Hose .2 Replace Hood Release Cable (Gas Engine Only) .3 Clean Up Components .4 Recoat Affected Parts (Radiator Support, Radiator, Battery Tray) .6

PARTS: List current dealer price plus 30% mark-up less $1.95 scrap allowance for replaced battery.

List GM Part No. of battery as the failed part.

List in sublet, amount for items required such as: sodium bicarbonate (baking soda) and/or paint.

.1 hour for clerical administration may be added to the above operations.

If additional parts and/or labor are required in excess of the operations above, including additives, the following labor operation should be used, which will require authorization:

Operation Operation Failure Code No. Labor Hours --------- ------------ ---- ----------- Includes any items 96 V2664 As Required requested above plus additional parts and/or labor as required.

PARTS: List current dealer price plus 30% mark-up less $1.95 scrap allowance for replaced battery. List GM Part No. of battery as the failed part.

.1 hour for clerical administration may be added to the above operations.

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.