CAMPAIGN: EGR VALVE MAY PLUG PASSAGE. Pontiac LeMans 1980

For 1990-2009 cars

# CAMPAIGN: EGR VALVE MAY PLUG PASSAGE

GENERAL MOTORS HAS DETERMINED THAT SOME 1980 PONTIACS EQUIPPED WITH 3.8L-2BBL. ENGINES MAY BE EMITTING POLLUTANTS IN EXCESS OF FEDERAL EMISSION STANDARDS. THE EGR VALVE MAY HAVE A PLUGGED PASSAGE CAUSING THE EGR VALVE NOT TO OPERATE, RESULTING IN AN INCREASE OF EXHAUST EMISSIONS. VEHICLES INVOLVED ----------------- ALL 1980 LEMANS, BONNEVILLES, FIREBIRDS, GRAND PRIX, AND SUNBIRDS EQUIPPED WITH FEDERAL 3.8L -2BBL. (VIN CODE A) BUICK ENGINES WITHOUT COMPUTER CONTROLLED EMISSION SYSTEMS. DEALER ACTION ------------- DEALERS ARE TO DETERMINE IF THE EGR VALVE IS OPERATING ON VEHICLES IN- VOLVED AT NO CHARGE TO THE OWNER REGARDLESS OF AGE OR MILEAGE ON VEHICLE. IF THE VALVE IS FUNCTIONING SATISFACTORILY, THE OWNER HAS BEEN REQUESTED TO HAVE THE EGR VALVE FUNCTION CHECKED AT 30,000 MILE INTERVALS AFTER THE INITIAL INSPECTION AND ALSO JUST PRIOR TO THE VEHICLE ACCUMULATING FIVE YEARS OR 50,000 MILES OF OPERATION. ALL INSPECTIONS SHOULD BE PERFORMED AT NO CHARGE TO OWNER. IF THE EGR VALVE IS DETERMINED TO BE INOPERATIVE, (PER TECHNICAL PROCEDURE OF THIS BULLETIN), THE EGR VALVE IS TO BE REPLACED. THIS REPLACEMENT WILL BE AT NO CHARGE, WITHIN FIVE YEARS OR 50,000 MILES, WHICHEVER OCCURS FIRST, FROM THE DATE OF ORIGINAL PURCHASE OF VEHICLE. IF THE VEHICLE IS NOT WITHIN THIS TIME AND/OR MILEAGE, REPLACEMENT OF THE VALVE WILL BE AT OWNER'S EXPENSE. IN THE INTEREST OF CUSTOMER SATISFACTION, DEALERA SHOULD VERIFY THAT THEY HAVE THE NECESSARY CAMPAIGN PART IN STOCK, BEFORE THEY SCHEDULE AN OWNER'S VEHICLE FOR THE RECALL INSPECTION. IF THERE IS EVIDENCE OF INTENTIONAL DISABLEMENT OF THE EGR SYSTEM, THE DEALER IS TO NOTIFY THE VEHICLE OWNER OF THIS CONDITION AND ASK THE OWNER IF HE/SHE WANTS THE SYSTEM RESTORED. THE COST OF RESTORATION WILL BE THE RESPONSIBILITY OF THE VEHICLE OWNER. VEHICLES IN USED CAR INVENTORY ARE TO BE CAMPAIGNED IN ACCORDANCE WITH THE GUIDELINES PRESCRIBED IN THIS BULLETIN, PRIOR TO RE-SALE OF THE VEHICLES. DEALER MATERIAL ---------------- A LISTING OF OWNER NAMES AND ADDRESSES FROM STATE MOTOR VEHICLES REGISTRATION RECORDS MAY HAVE BEEN FURNISHED TO ENABLE YOU TO FOLLOW- UP WITH OWNERS INVOLVED IN THIS CAMPAIGN. THE USE OF SUCH MOTOR VEHICLE REGISTRATION DATA FOR ANY PURPOSE IS A VIOLATION OF LAW IN SEVERAL STATES. ACCORDINGLY, YOU ARE TO LIMIT THE USE OF THIS LISTING IN THIS CAMPAIGN. OWNER NOTIFICATION ------------------ OWNERS OF VEHICLES INVOLVED IN THIS CAMPAIGN WILL BE NOTIFIED BY PONTIAC MOTOR DIVISION. (SAMPLE LETTER IS INCLUDED IN ACTUAL BULLETIN COPY.) TRANSFER OF VEHICLE ------------------- IF A VEHICLE HAS BEEN TRANSFERRED OR SOLD TO ANOTHER LOCATION, PLEASE FORWARD VEHICLE INFORMATION FOR THIS VEHICLE TO YOUR PONTIAC ZONE OFFICE FOR HANDLING WITH PROPER DEALER. TRANSFER CARDS MAY BE OBTAINED FROM YOUR DISTRICT SERVICE MANAGER. PARTS INFORMATION ------------------- DEALERS ARE TO ORDER EGR VALVES FROM THEIR LOCAL WDDGM (EGR GASKET IS INCLUDED WITH SERVICE PART): 1980 FEDERAL 3.8L, 2BBL. BUICK ENGINE WITHOUT COMPUTER CONTROLLED EMISSION SYSTEM ------------------------------------------- MODEL TRANSMISSION EGR VALVE TYPE SERVICE # ------- ------------ ---------- LEMANS AND GRAND PRIX AUTOMATIC 17066176 LEMANS MANUAL 17066236 BONNEVILLE/CATALINA/FIREBIRD AUTOMATIC 17066118 SUNBIRD AUTOMATIC 17066173 SUNBIRD MANUAL 17066175 DO NOT ORDER AN EGR VALVE FOR MANUAL TRANSMISSION VEHICLE UNLESS YOU HAVE A NEED FOR THIS PART, AS VERY FEW OF THESE VEHICLES WERE PRODUCED TO ENSURE THESE PARTS WILL BE OBTAINED AS SOON POSSIBLE, THEY SHOULD BE ORDERSD FROM WDDGM ON A C.I.D. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON ADVISE CODE (2). PART 1 - SERVICE PROCEDURE -------------------------- A. INSPECTION OF EGR VALVE- 1. RAISE VEHICLE HOOD AND COVER FENDERS. 2. WITH ENGINE AT OPERATING TEMPERATURE, RUNNING AT IDLE AND WITH TRANSMISSION IN "PARK", PLACE FINGERS BENEATH THE EGR VALVE IN ORDER TO CONTACT THE DIAPHRAGM. CAUTION: EGR VALVE MAY BE HOT. WEARING GLOVES IS RECOMMENDED TO ADVOID BURNING FINGERS. 3. RAPIDLY INCREASE SPEED TO APPROXIMATELY 2,000 RPM AND RETURN TO IDLE. REPEAT 4 OR 5 TIMES WITH A PAUSE EACH TIME. THE DIAPHRAGM SHOULD HAVE MOVED UP AND DOWN DURING THIS PROCEDURE IF THE SYSTEM IS FUNCTIONING PROPERLY. 4. IF NO UP OR DOWN MOTION WAS FELT WHEN PERFORMING THE ENGINE RPM INCREASE SEQUENCE, AS OUTLINED IN STEP 3, CHECK FOR VACUUM AT THE EGR VALVE HOSE AT THE HIGHER ENGINE SPEEDS. IF VACUUM IS PRESENT,REPLACE EGR VALVE, STEP B. 5. IF EGR VALVE FUNCTIONS PROPERLY, DO NOT REPLACE VALVE, INSTALL B.EGR VALVE REPLACEMENT 1. REMOVE AIR CLEANER ASSEMBLY. 2. REMOVE EGR VALVE ATTACHING BOLTS AND REMOVE VALVE. PROPERLY TAG VALVE AND HOLD FOR DISPOSITION BY PONTIAC ZONE. 3. REMOVE ALL TRACES OF GASKET MATERIAL FROM EGR VALVE MOUNTING SURFACE. DO NOT ALLOW ANY GASKET MATERIAL TO FALL INTO EGR PASSAGES. 4. OBTAIN CORRECT SERVICE EGR VALVE (REFER TO PARTS INFORMATION ABOVE) AND INSTALL NEW VALVE WITH NEW GASKE. TIGHTEN BOLTS TO 20 LB FT. 5. CHECK FOR PROPER EGR VALVE OPERATION, STEP A. 6. INSTALL AIR CLEANER AND INSTALL CAMPAIGN IDENTIFICATION LABEL. PART 2 CAMPAIGN IDENTIFICATION LABEL INSTALLATION PROCEDURE ----------------------------------------------------------- EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE 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 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. ADDITIONAL CAMPAIGN LABELS ARE AVAILABLE ON STATIONERY ORDER AS FORM 7201-709. DISPOSITION OF PARTS --------------------- REPLACED PARTS MUST BE HELD FOR DISPOSITION BY PONTIAC PERSONNEL. PARTS MUST HAVE A CLAIM TAG ATTACHED SHOWING THE REPAIR ORDER AND THE VIN OF THE VEHICLE FROM WHICH IT WAS REMOVED. ENCLOSED WITH THE COPY OF THIS BULLETIN --------------------------------------- A LIST OF THOSE VEHICLES INVOLVED WHICH OUR RECORDS INDICATE ARE IN YOUR GEOGRAPHICAL AREA IS ATTACHED 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 ATTACHED, OUR RECORDS INDICATE NO AFFECTED VEHICLES IN YOUR AREA. 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. 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 DEALER AT THE TIME THEY BRING THEIR VEHICLE TO HAVE THE CAMPAIGN PERFORMED. DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: (A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION.) FOR WARRANTY AND CREDITING INFORMATION, REFER TO ACTUAL BULLETIN COPY.

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.