CAMPAIGN: CARBURETOR THROTTLE BODY ASSEMBLY
MODEL AND YEAR: 1986 CHEVROLET CAPRICE CLASSIC STATION WAGONS EQUIPPED WITH 5.0L V8 ENGINE (RPO LV2)
General Motors has detemined that the carburetor throttle body assembly on certain 1986 Chevrolet Caprice Classic station wagons may have been damaged during vehicle assembly. As a result, the primary throttle valves may not provide the proper air/fuel mixture causing poor engine idle quality. In addition the transmission throttle valve (T.V.) cable may have been improperly adjusted.
To correct this condition, the carburetor throttle body assembly is to be replaced and the T.V. cable adjusted as outlined in the service procedure section of this bulletin.
VEHICLES INVOLVED
Involved are thirty-six (36) 1986 Chevrolet Caprice Classic station wagons equipped with 5.0L V8 engine (RPO LV2) listed as follows:
1G1BN35YOG9148416 1G1BN35Y1G9148506 1G1BN35Y2G9148420 1G1BN35Y3G9148510 1G1BN35Y3G9148426 1G1BN35Y4G9148516 1G1BN35Y5G9148430 1G1BN35Y6G9148520 1G1BN35Y6G9148436 1G1BN35Y7G9148526 1G1BN35Y8G9148440 1G1BN35Y8G9148647 1G1BN35Y9G9148446 1G1BN35Y3G9148653 1G1BN35YOG9148450 1G1BN35YOG9148657 1G1BN35YlG9148456 1G1BN35Y6G9148663 1G1BN35Y3G9148460 1G1BN35Y3G9148667 1G1BN35Y4G9148466 1G1BN35Y9G9148673 1G1BN35Y6G9148470 1G1BN35Y6G9148677 1G1BN35Y7G9148476 1G1BN35YlG9148683 1G1BN35Y9G9148480 1G1BN35Y9G9148687 1G1BN35YXG9148486 1G1BN35Y4G9148693 1G1BN35YIG9148490 1G1BN35YIG9148697 1G1BN35Y2G9148496 1G1BN35Y3G9148703 1G1BN35YOG9148500 1G1BN35YOG9148707
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 has no involved vehicles currently assigned.
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 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 correction according to instructions contained in this bulletin.
PARTS INFORMATION
The parts kits required for this campaign have been limited to the thirty-six (36) vehicles involved. They have also been made available on a one time only basis. Therefore dealers must contact their Branch Office to order parts. This should only be done, however, when contact has been made with an involved owner. The Branch will then contact Central Office and parts will be shipped directly to the involved dealer.
Parts are not to be ordered from or returned to General Motors Service Parts Operations (GMSPO).
When ordering the part kit refer to Campaign Number 86C21. The kit will consist of the following:
o Throttle Body Assembly o Gaskets (2) o TPS Adjustment Screw
SERVICE PROCEDURE
1. Open hood, install fender covers and disconnect the negative battery cable.
2. Remove air cleaner.
3. Disconnect the following:
o Throttle return spring. o Accelerator control cable at carburetor. o Transmission throttle valve (T.V.) cable at carburetor (see page 7A4-7 of the 1986 Caprice, Monte Carlo, El Camino Service Manual ST-329-86). o Cruise control linkage (if equipped). o All vacuum lines to carburetor. (Use of masking tape to label vacuum line position will ease reassembly). o Electrical connectors to carburetor. o Choke heat pipe. o Fuel line, at carburetor inlet.
4. Remove four carburetor mounting bolts and remove carburetor and flange (base) gasket.
5. Drain gasoline from carburetor and dispose of properly.
CAUTION:
Never drain or store gasoline in an open container due to the possibility of a fire or explosion.
6. Place carburetor on carburetor holding stand 09789-118, BT-3553 or equivalent.
7. Remove accelerator pump link retainer and disengage pump link from pump lever. Refer to Figure 1.
8. Remove air horn screws number 6 and 7 from carburetor. Refer to Figure 2.
9. Turn carburetor over and remove: a. Throttle body to float bowl attachment screws. b. Throttle body from carburetor. c. Pipe plug from rear of throttle body. d. Float bowl to throttle body gasket.
10. Disconnect and remove accelerator pump link from throttle body.
11. Install:
a. New float bowl to throttle body gasket on carburetor. (New gasket is supplied in throttle body kit. Refer to parts information in this bulletin.)
b. Accelerator pump link to new throttle body.
c. New throttle body to carburetor.
d. Throttle body to float bowl attachment screws and tighten screws.
12. Turn carburetor over. Install and tighten two air horn screws previously removed and tighten all other air horn screws in the sequence shown. Refer to Figure 2.
13. Connect accelerator pump link to pump lever and install retainer. Refer to Figure 1.
14. Using tool J 29030-B, BT-7610B, or equivalent, turn both mixture needles clockwise until lightly seated.
15. Turn each mixture needle counterclockwise 3 turns.
16. Clean carburetor sealing surface on intake manifold and install carburetor with new flange (base) gasket supplied in throttle body kit.
17. Install four carburetor mounting bolts and tighten to 16 Nm (12 lbs.ft) in the following sequence: a. Left rear b. Right front c. Right rear d. Left front
18. Reinstall the following: o Accelerator control cable. Make certain that the retainer tang is secured over the throttle lever stud. o Throttle return spring. o Transmission throttle valve (T.V.) cable and adjust as outlined on page 7A4-7 of the 1986 Caprice, Monte Carlo, El Camino Service Manual (ST-329-86). o Cruise control linkage, if equipped. Lube carburetor end with 1052541 lubricant prior to installation. o All vacuum lines to carburetor. o Electrical connectors to carburetor. o Choke heater pipe. (Tighten to 11 Nm 95 lbs.in) o Fuel line at carburetar inlet. (Tighten to 41 Nm 30 lbs.ft) o Pipe plug in rear of throttle body. Coat plug with 1052080 sealer and tighten to 1ONm (88 lbs.in).
19. Adjust the idle mixture needles as follows:
If the idle air bleed valve cover on the carburetor air horn has been previously removed, it will be necessary to adjust the idle air bleed valve setting prior to idle mixture needle adjustment. Refer to page 6El C2A-7 in the 1986 Caprice, Monte Carlo, El Camino Service Manual (ST-329-86) for idle air bleed valve adjustment.
a. Disconnect canister purge vacuum hose at canister and plug hose. b. Plug air cleaner vacuum line. c. Connect dwell meter to the mixture control solenoid test connector. d. With transmission in park, parking brake set and drive wheels blocked, start engine. Check for fuel leaks and correct if necessary: e. Allow engine to run until warm. (Upper radiator hose warm to touch and choke open.) Ensure fast idle cam is down completely. f. Place vehicle in drive. g. While idling in Drive adjust both mixture needles equally, in 1/8 turn increments, until dwell reading varies within the 25-35 range, attempting to be as close to 30 as possible. If reading is too low, turn mixture needles counterclockwise. If reading is too high, turn mixture needles clockwise. Allow time for dwell reading to stabilize after each adjustment. If dwell reading becomes fixed, the O2 sensor has probably cooled off (open loop). To warm the O2 sensor (closed loop) place transmission in park and flash the throttle 3 or 4 times. h. After adjustments are complete, seal the idle mixture needle opening in the throttle body, using silicone sealant, RTV rubber, or equivalent.
20. Adjust idle load compensator (ILC) as outlined on page 6El-C2A-11 of the 1986 Caprice, Monte Carlo, El Camino Service Manual (ST-329-86).
21. Check the throttle body secondary lever for proper adjustment of the following. Adjust if necessary.
o Secondary lockout. Refer to Figure 3. o Secondary closing. Refer to Figure 4. o Secondary opening. Refer to Figure 5.
22. Check, and if necessary, adjust the throttle position sensor (TPS) as outlined on page 6El-C2A-15 in the 1986 Caprice, Monte Carlo, El Camino Service Manual (ST-329-86). If TPS adjustment is required, remove existing TPS screw and install the new TPS screw included in the throttle body kit prior to making adjustment.
23. Following instructions on the vehicles emission control label, adjust engine fast idle. It is not necessary to adjust ignition timing.
24. Clear trouble codes in ECM memory by removing the 10 amp ECM fuse from fuse panel for 5 seconds.
25. If equipped with cruise control, check and if needed, adjust the servo rod length as described on page 9C-3 1986 Caprice, Monte Carlo, El Camino Service Manual (ST-329-86).
26. Inspect all carburetor linkage for proper operation.
27. Install air cleaner.
28. Install Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a spage to include the five digit dealer code of the dealer performing the campaign service. This infomation 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
Submit a Product Campaign Claim with the information indicated below:
* ** FAILED PARTS LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW FC OP HRS HRS AMT
INSTALL THROTTLE BODY 00 V3990 1.4 0.1 $30.58 ASSEMBLY AND ADJUST CARBURETOR
*Campaign Administrative Allowance **The $30.58 in the "Net Amount" Column covers 30% of dealer net when parts are furnished no charge by Chevrolet.
Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.
Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.
(Notification Used By Chevrolet Motor Division)
Dear Chevrolet Owner:
General Motors has detemined that the carburetor throttle body assembly on certain 1986 Chevrolet Caprice Classic station wagons may have been damaged during vehicle assembly. As a result the primary throttle valves may not provide the proper air/fuel mixture causing poor engine idle quality. In addition, the transmission throttle valve cable may have been improperly adjusted.
To correct this condition on your vehicle, your Chevrolet Dealer will install a new carburetor throttle body assembly and adjust the transmission throttle valve cable. This service will be performed for you at no charge.
Instructions for perfoming this repair have been sent to your Chevrolet Dealer. Please contact your Chevrolet Dealer to arrange a service date. The labor time to perfom this repair is approximately 80 minutes. Please ask your dealer if you wish to know how much additional time will be required to process your vehicle.
The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid owner reply card and returning it to us.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Chevrolet Motor Division GENERAL MOTORS CORPORATION
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.
