CAMPAIGN: PULSAIR PIPE HC/CO EMISSIONS. Pontiac T1000 1981

For 1990-2009 cars

# CAMPAIGN: PULSAIR PIPE HC/CO EMISSIONS

#### VEHICLES AFFECTED: 1981 PONTIAC T1000 MODELS EQUIPPED WITH 1.6L L-4 VIN CODE 9 ENGINE (RPO L17), MANUAL OR AUTOMATIC TRANSMISSION AND FEDERAL OR CALIPORNIA EMISSION SYSTEMS

#### CONDITION INVOLVED

General Motors has determined that certain 1981 Pontiac T1000 models equipped with 1.6L L-4 VIN code 9 engine (RPO L17), manual or automatic transmission and Federal or California emission systems may have certain deficiencies in the emission control system which may result in increased tailpipe hydrocarbon (HC) and carbon monoxide (CO) emissions.

The cause may be attributed to internal pulsair pipe corrosion (and eventual perforation causing an exhaust leak) which contaminates the pulsair solenold valve, possibly rendering the valve inoperative, which may result in increased emissions.

#### VEHICLES INVOLVED

All 1981 Pontiac T1000 models equipped with 1.6L L-4 VIN code 9 engine (RPO L17), manual or automatic transmission and Federal or California emission systems within the following vehicle breakpoints:

Plant From Through ----- ---- ------- Lakewood (A) S.O.P. E.O.P. Wilmington (Y) S.O.P. E.O.P.

#### DEALER CAMPAIGN RESPONSIBILITY

To correct this condition on vehicles involved, dealers are to perform the following:

1. Vehicles equipped with the BLUE-colored 4-port pulsair pipe assembly will require its replacement with the single port pulsair kit (Part Number 14076388) as outlined in the following PART I - SERVICE PROCEDURE.

(Vehicles equipped with the BLACK 4-port stainless steel pulsair pipe assembly DO NOT require the single port pulsair kit.)

2. All vehicles will require an inspection, cleaning (or replacement if necessary) of the pulsair solenoid spring and plunger assembly as outlined in the following PART II - SERVICE PROCEDURE.

3. Automatic transmission vehicles only. In addition to Steps 1 and 2, automatic transmission vehicles must have an air bleed valve harness assembly installed on the carburetor as outlined in the following PART III - SERVICE PROCEDURE.

Dealers are to service all vehicles subject to this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your 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 vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### OWNER NOTIFICATION

Owners of vehicles involved in this campaign, as records available to Pontiac Motor Division indicate, will be notified by Pontiac Motor Division (see copy of owner letter included with this bulletin).

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 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 the law in several states. Accordingly, you are urged to limit the use of this listing for the follow-up necessary to complete this campaign.

#### PART I - SERVICE PROCEDURE (SINGLE PORT PULSAIR PIPE INSTALLATION KIT)

1. Open the hood. Install fender cover.

2. If the vehicle has a BLUE pulsair assembly, repalce with a single tube kit assembly (part number 14076388). Refer to Figure 1.

The single tube assembly should be installed by mounting the single tube fitting in the number two (#2) cylinder exhaust port. The tube bracket should be attached to the stud (plug) that will be installed in the number one (#1) cylinder exhaust port. Plugs should be installed in remaining exhaust ports #3 and #4. The suppplied hose connects the single tube assembly to the pulsair solenoid housing.

(Vehicles with BLACK stainless steel 4-port assemblies do not require the 1-port kit)

#### PART II - SERVICE PROCEDURE (PULSAIR SOLENOID SPRING AND PLUNGER PROCEDURE

All vehicles require an inspection of the pulsair solenoid spring and-plunger (refer to Figure 2).

1. Remove spring clip from steel solenoid cap.

2. Remove cap and coil, plunger and plunger spring from the pulsair solenoid base.

If plunger is seized inside coil, use 8 inch gas pliers to remove. The rubber seal may have to be twisted off and the spring removed to obtain an adequate grip on the plunger stem. (Refer to Figure 2.)

CONSIDERABLE EFFORT MAY BE NECESSARY TO EXTRACT THE PLUNGER FROM THE COIL. (Breal loose with a back-and-forth rotating motion).

3. Inspect plunger, spring and rubber seal for operational movement. Inspect seal for secure attachment to plunger.

4. Wipe away any residue from components of solenoid assembly.

5. If necessary, replace plunger and spring assembly (Kit Part Number 22054247) to assure free movement of the plunger. Remove cardboard protector from new plunger assembly prior to installation.

6. With solenoid coil inverted and spring and plunger installed, make functional check of pulsair solenoid by turning ignition to "ON" (engine off), ground engine test lead of the ALDL connector and then connect the pulsair solenoid harness connector to the pulsair coil. The coil should energize, causing the plunger to retract. Ifthe plunger does not retract, determine the reason. Correct/repair the problem as required. If additional assistance is required, contact your district service manager.

7. Inspect the solenoid housing seat for damage. (Refer to Figure 3.) Replace housing, if required, with Part Number 22054245.

8. Reassemble solenoid.

9. If the BLUE 4-port Pulsair assembly was replaced by the 1-port kit (see PART I - SERVICE PROCEDURE), connect solenoid housing by using supplied hose.

10. Remove air cleaner cover and wipe off inside of air cleaner shell.

11. Remove crankcase vent pipe and blow out in a direction away from air cleaner.

12. On manual transmission vehicles, reconnect crankcase vent pipe and reinstall air cleaner cover.

13. On manual transmission vehicles, install Campaign Identification Label (as indicated in Part VI below), remove fender cover, and close hood.

#### PART III - SERVICE PROCEDURE (AIR BLEED VALVE INSTALLATION)

If the vehicle has an automatic transmission the installation of a staged orifice air bleed valve (Part Number 17085029) is required.

1. Remove air cleaner assembly.

2. Cut evaporative purge line about 1/2 inch outboard of fuel line (see View A, Figure 5).

3. Remove rubber isolator mounted on top of carburetor. Pierce 7/32" diameter hole on rear face of isolator, directly above the "V" shaped projection (see View C, Figure 5). The top of the hole should align with the top edge of the rib on the isolator. Reinstall the isolator on the carburetor torquing screws to 2.8-4.0 N.m. (25-35 in. lbs.).

4. Cut the EGR signal line about one inch outboard of the heater hose at the rear of the engine (see View B, Figure 5).

5. Assemble the air bleed valve and harness assembly to the engine (refer to Figure 4). Insert the tee fitting into the evaporative purge line. Press the 90 DEG elbow through the 7/32 inch hole in the carburetor isolator. Insert the "Y" plastic fitting into the EGR signal line. Assure hose from air bleed valve to isolator is dressed tight along side of vacuum break housing as shown.

6. Remove the screw which attaches the choke housing to the main body of the carburetor. Attach clip to the carburetor, using washer Part Number 11508426; torque screw to 0.6-1.7 N.m (5-14 in. lbs.).

7. Inspect the installation, making sure that there are no interference conditions with adjacent components.

8. Install air cleaner assembly.

9. Install Campaign Identification Label as indicated in PART IV, remove fender cover, and close hood.

#### PART IV - INSTALLATION OF 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-digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label on the radiator baffle where it is readily visible. Close hood. (Additional campaign labels are available on stationery order as Form 7901-709.)

#### PARTS INFORMATION

Parts are to be obtained from WDDGM from the chart on bulletin page 10.

To ensure that these 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). Parts removed from the involved vehicles are to be retained by the dealer in accordance with the current Service Policies and Procedures manual.

#### ENCLOSED WITH THE COPY OF THIS BULLETIN

A list of those vehicles involved, which records available to Pontiac Motor Division 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 are located 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.

#### CLAIM INFORMATION CHART

REPAIR PERFORMED PART FAILED LABOR NUMBER PART NO. LABOR HOURS

Tnspect pulsair pipe Inspect & clean solenoid Install air bleed kit & 17085029 washer(auto trans only) 11508426 Claim information V2820 *.3 (Manual *.4 (Automatic) Inspect pulsair pipe Inspect & clean solenoid 22054247 Replace spring & plunger 17085029 Install air bleed kit & 11508426 washer(auto trans only) Claim information 22054247 V2821 *.3 (Manual) *.4 (Automatic)

Inspect pulsair pipe Inspect & clean solenoid Install single port valve kit 14076388 Install air bleed kit & 17085029 washer(auto trans only) 11508426 Claim information 14076388 V2822 *.6 (Manual) *.8 (Automatic) Inspect pulsair pipe Inspect & clean solenoid Replace spring & plunger 22054247 Install single port valve kit 14076388 Install air bleed kit & 17085029 washer(auto trans only) 11508426 Claim information 14076388 V2823 *.6 (Manual) *.8 (Automatic)

Inspect pulsair pipe Inspect & clean solenoid Replace solenoid housing 22054245 Replace spring & plunger 22054247 Install single port valve kit 14076388 install air bleed kit & 17085029 washer (auto trans only) 11508426 Claim information 22054245 V2824 *.7 (Manual) *.9 (Automatic) Inspect pulsair pipe Inspect & clean solenoid Replace solenoid assembly **22034699 Install single port valve kit 14076388 Install air bleed kit & 17085029 washer(auto trans only) 11508426 Claim information 22034699 V2825 *.7 (Manual) *.9 (Automatic)

Submit a Warranty Campaign Claim based on the repairs performed and the labor information shown above.

*In addition dealerships will receive 0.1 hours 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 authorization.

**REPLACEMENT OF PART NUMBER 22034699 REQUIRES DISTRICT SERVICE MANAGER APPROVAL.

#### 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.

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.)

#### WARRANTY CREDIT

See chart in PARTS INFORMATION section for Labor information.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed on your warranty claim in the normal manner. 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.

Dear Pontiac Owner:

General Motors has determined that certain 1981 Pontiac T1000 models equipped with RPO L17 (1.6L L-4) engine, manual transmission Federal or California emission systems, may have certain deficiencies in the emission control system which may result in increased hydrocarbon (HC) and carbon monoxide (CO) emissions.

The cause may be attributed to internal pulsair pipe corrosion (and eventual perforation causing an exhaust leak) which contaminates the pulsair solenoid valve, possibly rendering the valve inoperative, which may result in increased emissions.

Please contact your Pontiac dealer on or after August 30, 1985 to arrange a service date to correct these conditions. Your dealer will inspect the pulsair solenoid and pipe assembly and replace as required. This service will be performed at no charge to you regardless of your vehicle's age or mileage.

Should your dealer find that your emission system has been intentionally disabled, other than to rectify pulsair leaks, at the time this correction is performed, you will be asked if you wish the system to be restored so that it will function as designed. The cost of such restoration will be your responsibility.

Instructions for making the correction(s) have been sent to your dealer. It is estimated that parts will be available on August 30, 1985. The labor time to perform this service is approximately one hour. Please allow additional time for your dealer to process your vehicle. As mentioned above, please contact your dealer to arrange a mutually satisfactory service date.

The enclosed Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the inspection to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid Owner Identification Reply Card ard returning it to us so that we may update our records. Should your dealer not schedule a service date within a reasonable time, you should contact your nearest Pontiac Zone Office either in person or by telephone for assistance. For your convenience the locations and telephone nmbers of the zone offices have been enclosed with this letter.

If your dealer or Pontiac zone office is unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturers Operation Division (EN-340), United States Environmental Protection Agency, 401 M Street, S.W., Washington, D.C. 20460; or you may call them at (202) 382-2495. To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be a lack of proper maintenance of your vehicle.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our product.

#### PONTIAC ZONE OFFICES

When Calling For Assistance, Please Ask For The Consumer Advisor

ATLANTA, GA 30328 JACKSONVILLE, FL 32211 5730 Glenridge Dr. Suite 800 Barnett Regency Tower (404) 257-3830 9550 Regency Square Blvd. (904) 724-2842 BOSTON Wellesley, MA 02181 KANSAS CITY, 45 William Street Overland Park, KS 66210 Wellesley Office Park 10800 Farley (617) 237-6910 (913) 383-4230

BUFFALO, LOS ANGELES* Williamsville, NY 14221 Westlake Village, CA 91361 150 Essjay Road Townsgate Executive Bldg. Ltd. (716) 634-7870 2659 Townsgate Rd., Suite 211 (213) 991-4310 CHARLOTTE, NC 28211 6525 Morrison Blvd. MEMPHIS, TN 38119 Suite 210 5350 Poplar Avenue (704) 336-5220 Suite 220 (901)761-4350 CHICAGO, Naperville, IL 60566 MILWAUKEE, 475 Alexis R. Shuman Blvd. Brookfield, WI 53005 (312) 961-6444 Suite 142 165 Bishop's Way CINCINNATI, OH 45246 (414) 784-0420 155 Tri-County Parkway P.O. Box 465616 MINNEAPOLIS, MN 55435 (513) 841-5807 Suite 300 7600 Parklawn Avenue CLEVELAND, (612) 830-4250 North Oldsted, OH 44070 25000 Great Northern NEWARK, Corporate Center Parsippany, NJ 07054 (216) 265-5800 9 Sylvan Way (201) 993-4016 DALLAS, Irving, TX 75062 NEW YORK, 130 E. Carpenter Fwy. Purchase, NY 10597-0890 (214) 659-5020 2500 Westchester Ave. (914)251-5235 DENVER, Englewood, CO 80110 OKLAHOMA CITY, OK 73112 Suite 810 Grand Centre Building Ist National Bank of Englewood Suite 265 333 W. Hampden Avenue 5400 Grand Blvd. (303) 398-7160 (405)843-2804

DETROIT, MI 48202 PHILADELPHIA, New Center One Bldg. Wayne, PA 19087 Suite 490 851 Duportail Rd. 3031 W. Grand Blvd. (215) 296-6560

HOUSTON, TX 77205 PITTSBURGH, PA 15275 16630 Imperial Valley Drive Bldg. #1, Suite 350 Suite 115 Cliff Mine Rd. (713) 931-7250 (412)928-5055

PORTLAND, OR 97223 *NOTE: The State of ALASKA is Lincoln Center, Suite 460 serviced by the Portland 10300 S. W. Greenburg, Rd. Zone. (503) 238-7911 The State of HAWAII is SAN FRANCISCO, serviced by the Los Angeles Fremont, CA 94538 Zone. 39465 Paseo Padre Parkway (415) 498-5151

ST. LOUIS, MO 63146 The Plaza Tower Ill West Port Plaza, Suite 1101 (314) 895-8650

WASHINGTON, Rockville, MD 20850 1395 Piccard Dr. (301) 258-1500

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.