CAMPAIGN: NOX EMISSIONS RELOCATE SOURCE OF EGR VACUUM. Pontiac J2000 1982

For 1990-2009 cars

# CAMPAIGN: NOX EMISSIONS RELOCATE SOURCE OF EGR VACUUM

GENERAL MOTORS HAS DETERMINED THAT SOME 1982 CHEVROLET CAVALIER MODELS EQUIPPED WITH RPO L46 1.8L ENGINE (VIN CODE G) AND CALIFORNIA EMISSIONS MAY BE EMITTING NOX POLLUTANTS IN EXCESS OF CALIFORNIA EMISSION STANDARDS. THIS MAY BE ATTRIBUTED TO THE E.G.R. VALVE VACUUM SIGNAL BECOMING INADEQUATE WITH INCREASED MILEAGE. TO CORRECT THIS CONDITION, THE SOURCE OF THE EGR VACUUM SIGNAL IS BEING RELOCATED TO PROVIDE INCREASED VACUUM, THEREBY REDUCING THE NOX EMISSION LEVEL. IN ADDITION, THE CARBURETOR SECONDARY VACUUM BREAK IS TO BE INSPECTED FOR PROPER OPERATION. VEHICLES INVOLVED CERTAIN 1982 CHEVROLET CAVALIER MODELS EQUIPPED WITH RPO L46 1.8L ENGINE (VIN CODE G) AND CALIFORNIA EMISSIONS WITH THE FOLLOWING PARAMETERS: PLANT FROM THROUGH SOUTHGATE CC100002 CC154029 JANESVILLE CJ130013 CJ139476 LORDSTOWN C7100009 C7231225 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 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 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 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. 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 PARTS REQUIRED TO COMPLETE THIS MODIFICATON 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). DESCRIPTION PART NUMBER EGR HARNESS MODIFICATION KIT 10045044 EACH KIT CONSISTS OF THE FOLLOWING: TUBE, CONNECTOR, STRAP, CAP, LABEL AND INSTRUCTION SHEET. VACUUM BREAK KIT 17068548 SERVICE PROCEDURE TO CORRECT THE ABOVE CONDITION, INSTALL EGR HARNESS MODIFICATION KIT, P/N 10045044, USING THE INSTRUCTION SHEET, P/N 10045045, INCLUDED IN THE KIT. SERVICE PROCEDURE 1. INSPECT AND REPAIR SECONDARY VACUUM BREAK AS REQUIRED. A. CHECK SECONDARY VACUUM BREAK FOR LEAKAGE BY APPLYING VACUUM WITH HAND VACUUM DEVICE (J-23738) OR EQUIVALENT. THE UNIT SHOULD HOLD THE VACUUM LEVEL. B. IF REPAIR IS INDICATED, REPLACE UNIT AS DETAILED IN THE 1982 CHEVROLET CAVALIER SHOP MANUAL (ST-366-82) PAGE 6C1-16. C. CHECK VACUUM BREAK FOR PROPER SETTING (27 DEG.). IF ADJUSTMENT IS REQUIRED, RESET USING SECONDARY VACUUM BREAK ADJUSTING PROCEDURE DETAILED IN FIGURE 6C1-8D OF THE 1982 CHEVROLET CAVALIER SHOP MANUAL (ST-366-82). II. REROUTE EGR SIGNAL LINE TO CANISTER PURGE PORT OF CARBURETOR TO PROVIDE EARLIER SIGNAL. (REFER FIGURE 1). A. CONNECT ONE END OF THE 18" EMISSION HOSE TO THE BASE OF THE Y CONNECTOR. B. REMOVE THE CANISTER PURGE CONTROL HOSE FROM THE REAR OF THE CARBURETOR (PORT B) AND CONNECT THE OTHER END OF THE 18" HOSE TO THE CARBURETOR PORT. C. RECONNECT THE CANISTER PURGE CONTROL HOSE TO THE SMALL NIPPLE OF THE Y CONNECTOR. D. REMOVE THE EGR SIGNAL HOSE FROM THE REAR OF THE CARBURETOR (PORT C) AND INSTALL THE RUBBER CAP ON THE CARBURETOR PORT TO SEAL THIS SIGNAL LOCATION. E. CONNECT THE EGR SIGNAL HOSE TO THE REMAINING NIPPLE OF THE Y CONNECTOR. F. STRAP THE NEW EMISSION HOSE TO THE POWER STEERING LINE OR ENGINE WIRING HARNESS TO PREVENT IT FROM MOVING AROUND. III. PERFORM A FUNCTIONAL CHECK OF THE REVISED EGR SYSTEM USING THE PROCEDURE DETAILED IN THE 1982 CHEVROLET CAVALIER SHOP MANUAL (ST-366-82) PAGE 6E-44. IV. ON AUTOMATIC TRANSMISSIONS ONLY, RESET INITIAL TIMING TO 8 DEGREES BTDC USING PROCEUDRE FOUND IN THE 1982 CHEVROLET CAVALIER SHOP MANUAL (ST-366-82) PAGE 6D-19. V. REMOVE OLD TUNE-UP LABEL LOCATED ON SHOCK TOWER AND INSTALL NEW LABEL (P/N 14100959). DO NOT INSTALL THE NEW LABEL OVER THE OLD LABEL. (REFER TO FIGURE 2). VI. 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 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 *** FAILED PARTS LABOR LABOR OTHER REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS INSPECT VACUUM BREAK, INSTALL EGR HARNESS MODIFICATION KIT AND NEW TUNE-UP LABEL. NO FURTHER ACTION REQUIRED. 1 10045044 00 V3290 .4 .1 INSPECT VACUUM BREAK, INSTALL EGR HARNESS MODIFICATION KIT AND NEW TUNE-UP LABEL. RESET TIMING VEHICLE EQUIPPED WITH AUTO- MATIC TRANSMISSION 1 10045044 00 V3291 .6 .1 INSPECT AND REPLACE SECONDARY VACUUM BREAK, INSTALL EGR HARNESS MODIFICATION KIT AND NEW TUNE-UP LABEL. 2 10045044 00 V3292 1.1 .1 INSPECT AND REPLACE SECONDARY VACUUM BREAK, INSTALL EGR HARNESS MODIFICATION KIT AND NEW TUNE-UP LABEL, RESET TIMING, VEHICLE EQUIPPED WITH AUTO- MATIC TRANSMISSION 2 10045044 00 V3293 1.3 .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.

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.