PRODUCT CAMPAIGN:1980 A-BODY STATION WAGONS - ELECT R. DEF.. Pontiac LeMans 1980

For 1990-2009 cars

# PRODUCT CAMPAIGN:1980 A-BODY STATION WAGONS - ELECT R. DEF.

THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT, AS AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A REASONABLE TIME AFTER THE OWNER HAS TENDERED IT FOR REPAIR. A FAILURE TO ADEQUATELY REPAR 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 OWNER 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 PONTIAC ZONE OFFICE IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE DAYS OF THE AGREED SERVICE DATE. IF THE CONDITION IS NOT REMEDIED WITHIN A REASONABLE TIME, THE OWNERS ARE INSTRUCTED HOW TO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION.

THE NATIONAL HIGHWAY TRAFFIC SAFETY ASSOCIATE ADMINISTRATOR HAS MADE AN INITIAL DETERMINATION THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS WITH RESPECT TO SOME 1979 AND 1980 PONTIAC LEMANS INTERMEDIATE SIZE STATION WAGONS, EQUIPPED WITH ELECTRIC REAR WINDOW DEFOGGERS AND ASSEMBLED DURING THE 1979 CALENDAR YEAR. SPECIFICALLY, THE ASSOCIATE ADMINISTRATOR BASED HIS INITIAL DETERMINATION ON AN INVESTIGATION REPORT WHICH CONCLUDES THAT:

"THE DEFOGGER BACKLIGHTS (WINDOWS) CONTAIN A DEFECT WHICH CAUSES THE GLASS TO SHATTER WITHOUT IMPACT DURING OR SOME TIME AFTER THE USE OF THE DEFOGGER. THE DRIVER DISTRACTION AND THE EXPLOSION OF BROKEN OR HOT GLASS INTO THE PASSENGER COMPARTMENT OF THE VEHICLE CREATES AN UNREASONABLE RISK OF ACCIDENT OR INJURY TO THE OCCUPANTS OF THE SUBJECT VEHICLE, AS WELL AS PEDESTRIANS AND DRIVERS OF OTHER CARS ON THE ROAD."

A POSSIBILITY EXISTS THAT PORTIONS OF THE VERTICAL ELECTRICAL STIPS (BUSS BARS) ON THE REAR WINDOW MAY DETERIORATE THROUGH CONTACT WITH A PARTICULAR MAKE OF RUBBER WEATHERSTRIP MATERIAL. DURING OPERATION OF THE DEFOGGER, THIS CAN CAUSE LOCALIZED HOT SPOTS WHICH COULD, IN CERTAIN INSTANCES, RESULT IN BREAKAGE OF THE REAR WINDOW GLASS.

BASED ON THIS INITIAL DETERMINATION, GENERAL MOTORS HAS DECIDED TO REPAIR THESE BUSS BARS, AS NECESSARY, AT NO CHARGE TO OWNERS OF THESE VEHICLES.

DEALERS WILL INSPECT EACH VEHICLE TO SEE IF IT WAS ASSEMBLED WITH A PARTICULAR MAKE OF WEATHERSTRIP (SEE FIGURE 2). IF IT WAS NOT, NO FURTHER ACTION WILL BE NECESSARY AND DEALERS ARE INSTRUCTED TO SO ADVISE THE OWNER. IF THE PARTICULAR WEATHERSTIP IS PRESENT, THE BUSS BAR WILL BE REPAIRED BY APPLICATION OF NEW SILVER CONDUCTOR MATERIAL. REPLACEMENT OF THE WEATHERSTIP WILL NOT BE NECESSARY BECAUSE IT WILL NOT CAUSE THE REPAIRED BUSS BAR TO DETERIORATE.

#### NOTE: NEAR THE BEGINNING OF THE 1980 CALENDAR YEAR, GENERAL MOTORS RELEASED A SERVICE REAR WINDOW GLASS WHICH MOVED THE BUSS BARS INBOARD (SEE FIGURE 1). THE SERVICE GLASS IS IDENTIFIED BY A WIDE BLACK OUT BAND AROUND ITS OUTSIDE EDGE. IF A SERVICE GLASS HAS BEEN PREVIOUSLY INSTALLED IN ANY VEHICLE, NO FURTHER ACTION IS REQUIRED, REGARDLESS OF THE WEATHERSTRIP IDENTIFIED.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1979 AND 1980 PONTIAC LEMANS MODEL STATION WAGONS (D35 AND F35 MODELS) EQUIPPED WITH UPC CODE C49, REAR WINDOW DEFOGGER, WITHIN THE FOLLOWING VEHICLE IDENTIFICATION NUMBER BREAKPOINTS:

PLANT FROM UP TO

1979 BALTIMORE 9B119493 END OF PRODUCTION PONTIAC 9P559247 END OF PRODUCTION

1980 BALTIMORE START OF PRODUCTION AB110120 PONTIAC START OF PRODUCTION AP534054

DEALER CAMPAIGN RESPONSIBILITY

DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN, 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.

OWNER NOTIFICATION

OWNERS OF VEHICLES INVOLVED IN THIS CAMPAIGN WILL BE NOTIFIED BY PONTIAC MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN.)

#### NOTICE: 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.

THE COMPUTER 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. IF A LIST OF VEHICLES IS NOT ATTACHED, OUR RECORDS INDICATE NO AFFECTED VEHICLE(S) IN YOUR AREA.

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.

INSPECTION PROCEDURE

IDENTIFY VEHICLE BY VEHICLE IDENTIFICATION NUMBER AS BEING WITHIN APPLICABLE VIN BREAKPOINT RANGE AND EQUIPPED WITH UPC CODE C49 REAR WINDOW DEFOGGER.

SERVICE PROCEDURE

INSPECTION AND REPAIR OF REAR WINDOW DEFOGGER

ON 1979 AND EARLY 1980 CARS, THE WEATHERSTRIPS USED IN THE LIFT GLASS OPENING WERE SUPPLIED BY TWO DIFFERENT MANUFACTURERS: SHELLER-GLOBE AND GENERAL TIRE.

ON THOSE VEHICLES EQUIPPED WITH GENERAL TIRE WEATHERSTRIPS, IT IS POSSIBLE FOR A CONDITION TO DEVELOP WHICH CAUSES THE BUSS BARS ON THE HEATED GLASS (SEE FIGURE 3) TO LOSE ELECTRICAL CONDUCTIVITY. THIS LOSS OF CONDUCTIVITY INCREASES THE OPERATING TEMPERATURES TO A POINT AT WHICH THE GLASS MAY BREAK.

ALL VEHICLES EQUIPPED WITH THE GENERAL TIRE WEATHERSTRIP AND C49 OPTION WILL REQUIRE THE COMPLETE REPAIR AS DESCRIBED IN THIS BULLETIN. THE REWORK INVOLVES ADDING A LAYER OF A SPECIAL CONDUCTIVE EPOXY TO THE BUSS BAR ON THE REAR WINDOW GLASS.

#### NOTE: NEAR THE BEGINNING OF THE 1980 CALENDAR YEAR, GENERAL MOTORS RELEASED A SERVICE REAR WINDOW GLASS WHICH MOVED THE BUSS BARS INBOARD (SEE FIGURE 1). THE SERVICE GLASS IS IDENTIFIED BY A WIDE BLACK-OUT BAND AROUND ITS OUTSIDE EDGE. IF A SERVICE GLASS HAS BEEN PREVIOUSLY INSTALLED IN ANY VEHICLE, NO FURTHER ACTION IS REQUIRED, REGARDLESS OF THE WEATHERSTRIP IDENTIFIED.

IDENTIFICATION OF WEATHERSTRIP MARKINGS ARE SHOWN IN FIGURE 2.

THOSE VEHICLES THAT ARE INSPECTED AND FOUND TO HAVE SHELLER-GLOVE WEATHERSTRIPS ARE NOT AFFECTED AND DO NOT REQUIRE REPAIR. THE REPAIR PROCEDURES ARE SHOWN IN FIGURES 3 THROUGH 7.

INSTALL CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS SERVICE 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 VEHICLE WAS CAMPAIGNED. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT PEN. WHEN INSTALLING LABEL, CLEAN THE SURFACE OF THE RADIATOR UPPER MOUNTING PANEL IN THE AREA OF EMISSION LABEL AND APPLY THE CAMPAIGN LABEL.

PARTS INFORMATION

THE MATERIAL REQUIRED TO PERFORM THE REWORK HAS BEEN PACKAGED IN KIT FORM UNDER P/N 9636066. THESE KITS ARE AVAILABLE THROUGH G.M. WAREHOUSING AND DISTRIBUTION DIVISION (GMWDD). TO ENSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE THEY SHOULD BE ORDERED FORM GMWDD ON A CIO ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2). TO ENSURE ADEQUATE AVAILABILITY OF THIS PART, DO NOT ORDER PARTS UNTIL AFTER MARCH 2, 1981. INITIAL ORDERS SHOULD BE LIMITED TO IMMEDIATE NEEDS.

TO BE FORWARDED SHORTLY UNDER SEPARATE COVER:

A LIST OF THOSE VEHICLES INVOLVED, WHICH OUR RECORDS INDICATE ARE IN YOUR GEOGRAPHICAL AREA, WILL BE SENT FOR YOUR FOLLOW UP. ADVISE THE ZONE IF VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. (IF A LIST OF VEHICLES IS NOT RECEIVED SHORTLY, OUR RECORDS INDICATE NO AFFECTED VEHICLE(S) IN YOUR AREA).

CAMPAIGN IDENTIFICATION LABELS WILL BE FURNISHED FOR INSTALLATION ON THE RADIATOR UPPER MOUNTING PANEL TO IDENTIFY CARS COMPLETED.

IF A VEHICLE HAS BEEN TRANSFERRED OR SOLD TO ANOTHER LOCATION, PLEASE FORWARD THE NEW NAME AND ADDRESS OF THE VEHICLE TO YOUR PONTIAC ZONE OFFICE.

INSPECTION PROCEDURE

1. INSPECT REAR WINDOW GLASS TO DETERMINE IF SERVICE GLASS HAS BEEN INSTALLED (FIGURE 1). IF SERVICE GLASS HAS BEEN INSTALLED, NO FURTHER ACTION IS REQUIRED. INSTALL CAMPAIGN IDENTIFICATION LABEL.

2. DETERMINE THE WEATHERSTRIP SUPPLIER. OPEN THE LIFT GLASS, LIFT OUTER LIP OF WEATHERSTRIP AND INSPECT THE UPPER RIGHT OR LEFT CORNER OF THE WEATHERSTRIP IN THE AREA OF THE RADIUS (FIGURE 2).

3. ONE (1) HOLE INDICATES SHELLER GLOBE WEATHERSTRIP. THE INSPECTION IS COMPLETE AND NO FURTHER ACTION IS NECESSARY. INSTALL CAMPAIGN IDENTIFI- CATION LABEL.

4. THREE (3) HOLES INDICATE GENERAL TIRE WEATHERSTRIP. THE COMPLETE REWORK IS TO BE PERFORMED ON THESE CARS.

REPAIR PROCEDURE

1. REMOVE BACK GLASS ASSEMBLY FROM THE CAR AND PLACE ON A CLEAN PROTECTED SURFACE.

2. WORKING ON THE INSIDE OF THE GLASS, APPLY MASKING TAPE TO GLASS 3/8" INBOARD OF BUSS BAR MATERIAL AND TO THE TOP OF METAL WINDOW FRAME ON EACH SIDE OF GLASS (FIGURE 4).

3. REMOVE BLACK RESIDUE FROM BOTH BUSS BARS AND EXPOSED GRIDS USING THE 3M SCOTCH BRIGHT (GRAY) PAD PROVIDED. LIGHT PRESSURE SHOULD BE APPLIED TO THE PAD UNTIL THE BUSS BARS TURN A SILVER GRAY COLOR. REMOVE ONLY AS MUCH BUSS BAR MATERIAL AS NECESSARY TO ASSURE A REASONABLY CLEAN SURFACE. THE GRIDS ARE ESPECIALLY DELICATE AND CARE SHOULD BE TAKEN TO ASSURE THE SCOTCH BRITE CLEANING WILL NOT CAUSE BREAKS OR OPENS IN THE GRID LINES NEXT TO THE BUSS BAR.

4. REMOVE MASKING TAPE FROM GLASS AND GLASS FRAME. THEN CLEAN GLASS SURFACE WITH A WAX AND GREASE REMOVER SUCH AS PREP SOL. PRE KLEANO, ACRYLIC CLEAN, SHER WILL CLEAN OR EQUIVALENT. WIPE SURFACE WITH A CLEAN CLOTH AND ALLOW TO DRY.

5. WITH SCISSORS, ROUND CORNERS OF COPPER TAPE (SUPPLIED IN THE KIT) AS SHOWN ABOVE. REMOVE BACKING FROM 1/2" X 6" COPPER TAPE AND APPLY TO INBOARD EDGE OF BOTH BUSS BARS FROM THE THIRD TO THE EIGHTH GRID LINE (FIGURE 5). APPLY PRESSURE TO TAPE SURFACE TO REMOVE AIR POCKETS.

6. MASKS SUPPLIED IN KIT ARE TO BE APPLIED TO LEFT AND RIGHT SIDES. CUT MAST AT POINTS "A" AND "B" (FIGURE 6). APPLY LARGE PORTION OF MASK TO GLASS 3/8" INBOARD OF BUSS BAR. THEN APPLY SMALL 3/16" STRIP PORTION OF THE GLASS WITH EDGE OF MASK ALONG THE OUTER EDGE OF BUSS BAR.

7. APPLY MASKING TAPE OVER GLASS FRAME AND OUTBOARD EDGE OF MASK TO ELIMINATE EXCESS CLEAN UP (SECTOIN A-A).

8. FORM A PIECE OF MASKING TAPE (FIGURE 8) AND APPLY OVER TOP OF EACH BRASS CONTACT PLATE (FIGURE 7).

9. TO INCREASE THICKNESS OF EPOXY WHICH WILL BE APPLIED OVER BUSS BAR, APPLY MASKING TAPE OVER MASK FROM SECOND GRID LINE TO NINTH GRID LINE (FIGURE 7).

10. MIX ONE PACKAGE OF EPOXY MATERIAL FOR TWO MINUTES AND APPLY TO TOTAL CUT OUT AREA OF MASK USING A STIFF 2" OR 3" PUTTY KNIFE. THE KNIFE MUST MAINTAIN LIGHT PRESSURE AGAINST THE MASK SURFACE DURING APPLICA- TION OF THE EPOXY MATERIAL TO ASSURE A SMOOTH LEVEL APPLICATION OF MATERIAL (FIGURE 7).

11. REMOVE MASK AND MASKING TAPE FROM GLASS AND GLASS FRAME.

12. CURE THE EPOXY BY PASSING A HAND-HELD HEAT GUN (WITH A RANGE OF 350 DEG ) BACK AND FORTH FOR FIVE MINUTES. EPOXY IS CURED WHEN LIGHT FINGERNAIL PRESSURE WILL NOT MAKE AN IMPRESSION IN THE MATERIAL.

13. REPEAT PROCEDURE ON OPPOSITE SIDE, AFTER MATERIAL HAS CURED CLEAN EXCESS EPOXY MATERIAL FROM AROUND NEW BUSS BARS.

14. REINSTALL GLASS ASSEMBLY TO THE VEHICLE.

15. TEST ALL GRID LINES TO DETERMINE IF THEY ARE OPERATIONAL AND REPAIR GRIDS AS REQUIRED USING REMAINING SILVER EPOXY MATERIAL, FOLLOWING STANDARD PROCEDURE OUTLINED IN SECTION NO 10 OF THE FISHER SERVICE MANUAL.

RECORDING COMPLETION

CAMPAIGN COMPLETION WILL BE RECORDED FROM "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." OWNERS ARE BEING ASKED TO PRESENT THE OWNER REPLY CARD FOR IDENTIFICATION TO THEIR DEALER AT THE TIME THEY BRING IN THEIR VEHICLE TO HAVE THE CAMPAIGN PERFORMED.

#### NOTE: THE SPECIAL COMPUTER DATA CARDS ARE NO LONGER BEING USED FOR REPORTING COMPLETION AND THIS MAKES IT IMPERATIVE THAT DEALERS SUBMIT A WARRANTY CLAIM.

ADDITIONAL CAMPAIGN LABELS ARE AVAILABLE FROM YOUR ZONE OFFICE SERVICE DEPARTMENT.

DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

(NOTICE: A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.)

WARRANTY CREDIT

A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN.

(LABOR)

THE NEW LABOR OPERATIONS LISTED BELOW ARE ASSIGNED SPECIFICALLY FOR THIS CAMPAIGN.

FAILURE LABOR LABOR *OTHER CODE OPERATION HOURS HOURS

1. 96 V0750 0.2 HOUR 0.1 HOUR 2. 96 V0751 1.5 HOUR 0.1 HOUR

DESCRIPTION: 1. INSPECT WEATHERSTRIP. 2. INSPECT AND INSTALL KIT, CHECK GRIDS.

USE ONLY ONE OF THE LABOR OPERATIONS PER VEHICLE.

IN THE EVENT AN OWNER INCURRED DEFOGGER REAR WINDOW REPLACEMENT EXPENSE RELATING TO THE CONDITION O IN THIS BULLETIN AND REQUESTS REIMBURSEMENT, YOU ARE TO CONTACT YOUR LOCAL ZONE OFFICE FOR ASSISTANCE.

*"IN ADDITION, DEALERSHIPS WILL RECEIVE 0.1 HOUR CREDIT FOR DEALER ADMINISTRATIVE SERVICES ASSOCIATED WITH THIS CAMPAIGN. THE 0.1 HOURS ALLOWANCE IS TO BE ENTERED IN THE "OTHER LABOR HOURS" FIELD WITH EACH CAMPAIGN REPAIR LISTED FOR CREDIT. THIS ENTRY WILL NOT REQUIRE ZONE AUTHORIZATION."

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

PARTS WILL BE CREDITED AT DEALER NET, PLUS 30% DEALER HANDLING ALLOWANCE.

(CREDITING)

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS MUST CONTAIN ALL INFORMATION REQUIRED AND SHOULD LIST THE LABOR OPERATION AS OUTLINED.

REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE CAMPAIGN WILL NOT BE PAID.

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.