CAMPAIGN: PRODUCT EMISSION PULSAIR PIPE HC/CO EMISSIONS

Model and Year: 1981 CHEVROLET CHEVETTE MODELS EQUIPPED WITH RPO L17 (1.6L L4) ENGINE - MANUAL OR AUTOMATIC TRANSMISSION AND FEDERAL OR CALIFORNIA EMISSION SYSTEMS

TO: ALL CHEVROLET DEALERS

General Motors has determined that certain 1981 Chevrolet Chevette models equipped with RPO L17 (1.6L L4) engine, 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 solenoid valve, possibly rendering the valve inoperative, which may result in increased emissions.

VEHICLES INVOLVED

Certain 1981 Chevrolet Chevette models equipped with RPO L17 (1.6L L4) engine, manual or automatic transmission and Federal or California emission systems within the following vehicle parameters:

Plant From Through ----- ---- ------- Lakewood BA100001 BA270020

Wilmington BY100001 BY363604

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 IDENTIFICATION

All owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of Owner Letter included with this bulletin).

DEALER RESPONSIBILITY

Dealers are to service all vehicles subject to this campaign at no charge to owners under the Emissions Control Systems Warranties, regardless of mileage, age of vehicle, or ownership, from this time forward.

Whenever a vehicle subject to this campaign is taken into your used vehicle inventory, or it is in your dealership for servie in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

In the interest of customer satisfaction, dealers should verify that they have the necessary campaign parts in stock, before they schedule an owners vehicle for this service.

If there is evidence of intentional disablement of the emission system, other than to rectify pulsai leakage, 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.

CAMPAIGN SERVICE REQUIREMENTS

Step 1. Vehicles equipped with the 4 port (blue) pulsair pipe assembly will require its replacement with the single port pulsair kit P/N 14076388.

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

Step 2. All Vehicles. Inspect and clean or replace as necessary, the pulsair solenoid spring and plunger assembly as outlined in the service procedure.

Step 3. Automatic transmission vehicles only. In addition to Step 1 and 2 automatic transmission vehicles must have an air bleed valve harness assembly installed on the carburetor.

SERVICE PROCEDURE

STEP 1 - SINGLE PORT PULSAIR PIPE INSTALLATION KIT

Replace 4 port (blue) pulsair assembly with a single tube kit assembly (P/N 14076388). (Refer 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 exhaust ports #3 and #4. The supplied hose connects the single tube assembly to the pulsair solenoid housing.

VEHICLES WITH THE BLACK STAINLESS STEEL 4 PORT ASSEMBLIES DO NOT REQUIRE THE 1 PORT KIT.

STEP 2 - PULSAIR SOLENOID SPRING AND PLUNGER PROCEDURE

All vehicles require an inspection of pulsair solenoid spring and plunger. (Refer 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 FIGURE 2) CONSIDERABLE EFFORT MAY BE NECESSARY TO EXTRACT THE PLUNGER FROM THE COIL. (BREAK 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 P/N 22054247) assuring free movement of the plunger.

REMOVE CARDBOARD PORTECTOR 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. If the plunger does not retract, determine the reason, correct/repair the problem as required. If additional assistance is required, contact your area service manager.

7. Inspect the solenoid housing seat for damage. Replace housing, if required, with P/N 22054245 (See Figure 3).

8. Reassemble solenoid.

9. If 4 port pulsair assembly (blue) required replacement by 1 port kit, connect solenoid housing using supplied hose.

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

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

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

13. Install Campaign completion label (manual transmission).

STEP 3

Automatic transmission vehicles require the installation of a staged orifice bleed valve (P/N 17085029).

Air Bleed Valve Installation Instructions

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" dia. hole on rear face of isolator, directly above the "V" shaped projection (See View C, figure 5). The top of the hole should be coincident with the top edge of the rib on the insolator. 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 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 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 label.

PARTS INFORMATION

Parts required to complete this modification are to be obtained from the 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 order on an advise code (2).

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

MANUAL TRANSMISSION

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- ---------- ----- ------ 00 V2820 .3 .1

DESCRIPTION: Inspect pulsair pipe, vehicle equipped with stainless steel 4 port pulsair assembly. Inspect and clean pulsair solenoid. No further action required.

CLAIM INFORMATION

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- --------- --------- ---- --------- ----- ----- 2 22054247 00 V2821 . 3 .1

DESCRIPTION: Inspect pulsair pipe, vehicle equipped with stainless steel 4 port pulsair assembly. Replace pulsair solenoid spring and plunger P/N 22054247.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- ---------- ---------- ---- --------- ----- ----- 1 14076388 00 V2822 . 6 .1

DESCRIPTION: Inspect, clean pulsair solenoid. Install pulsair single port valve kit P/N 14076388.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- --------- ---------- ---- --------- ----- ----- 3 14076388 00 V2823 . 6 .1

DESCRIPTION: Inspect and replace pulsair solenoid spring and plunger P/N 22054247. Install pulsair single port valve kit P/N 14076388.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- ---------- --------- ---- --------- ----- ----- 4 22054245 00 V2824 .7 .1

DESCRIPTION: Inspect and replace pulsair solenoid spring and plunger P/N 22054247. Replace pulsair solenoid housing P/N 22054245. Install pulsair single port valve kit P/N 14076388.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- --------- ---------- ---- ---------- ----- ----- 2 22034699 00 V2825 .7 .1

DESCRIPTION: Replace pulsair solenoid assembly, P/N 22034699. Install pulsair single port valve kit, P/N 14076388.

P/N 22034699 REQUIRES CHEVROLET AREA SERVICE MANAGER'S APPROVAL FOR REPLACEMENT.

AUTOMATIC TRANSMISSION

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- --------- ----- ----- 2 17085029 00 V2830 .4 .1

DESCRIPTION: Inspect and clean pulsair solenoid. Install air bleed valve kit P/N 17085029 and P/N 11508426 washer. Vehicle equipped with stainless steel 4 port pulsair assembly.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- --------- ----- ----- 4 22054247 00 V2831 . 4 .1

DESCRIPTION: Inspect and replace pulsair solenoid spring and plunger P/N 22054247. Install air bleed valve kit P/N 17085029, P/N 11508426 washer. Vehicle equipped with stainless steel 4 port pulsair assembly.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- --------- ---------- ---- --------- ----- ----- 3 14076388 00 V2832 .8 .1

DESCRIPTION: Inspect and clean pulsair solenoid. Install pulsair single port valve kit P/N 14076388. Install air bleed valve kit P/N 17085029 and P/N 11508426 washer.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- ---------- ----- ----- 5 14076388 00 V2833 .8 .1

DESCRIPTION: Inspect and replace pulsair solenoid spring and plunger P/N 22054247. Install pulsair single port valve kit P/N 14076388. Install air bleed valve kit P/N 17085029 and 11508426 washer.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- ---------- ----- ----- 6 22054245 00 V2834 .9 .1

DESCRIPTION: Inspect and replace pulsair solenoid spring and plunger P/N 22054247. Install pulsair single port valve kit P/N 14076388. Install air bleed valve kit P/N 17085029 and 11508426 washer. Replace pulsair solenoid housing P/N 22054245.

Parts Failed **Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours ----- -------- --------- ---- --------- ----- ----- 4 22034699 00 V2835 .9 .1

DESCRIPTION: Replace pulsair solenoid assembly PIN 22034699. Install air bleed valve kit P/N 17085029 and 11508426 washer. Install pulsair single port valve kit P/N 14076388.

P/N 22034699 REQUIRES CHEVROLET AREA SERVICE MANAGER'S APPROVAL FOR REPLACEMENT.

*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 and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim submission.

In addition to the normal dealer claim information a "Claim Information Chart," has been prepared on page 12 to assist Dealer Personnel in identifying the repair categories of each vehicle involved.

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.

CLAIM INFORMATION CHART

TRANSMISSION

MANUAL

PART FAILED LAB REPAIR PERFORMED NUMBER PC PART NO. LABOP HRS ---------------- ------ -- -------- ----- --- INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION V2820 .3 INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SPRING & PLUNGER 22054247 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 2 22054247 V2821 .3

INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENDID INSTALL SINGLE PORT VALVE KIT 14076388 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 1 14076388 V2822 .6

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 3 14076388 V2823 .6

INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SOLENOID HOUSING 22054245 REPLACE SPRING & PLUNGER 22054247 INSTALL SINGLE PORT VALVE KIT 1407639e INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 4 22054245 V2824 .7 INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SOLENDID ASSEMBLY** 22034699 INSTALL SINGLE PORT VALVE KIT 14076388 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 2 22034699 V2825 .7

AUTOMATIC

PART FAILED LAB REPAIR PERFORMED NUMBER PC PART NO. LABOP HRS ---------------- ------- -- --------- ----- --- INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 2 17085029 V2830 .4 INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SPRING & PLUNGER 22054247 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 4 22054247 V2831 .4

INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENDID INSTALL SINGLE PORT VALVE KIT 14076388 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 3 14076388 V2832 .8

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 5 14076388 V2833 .8

INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SOLENOID HOUSING 22054245 REPLACE SPRING & PLUNGER 22054247 INSTALL SINGLE PORT VALVE KIT 1407639e INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 6 22054245 V2834 .9 INSPECT PULSAIR PIPE INSPECT & CLEAN SOLENOID REPLACE SOLENDID ASSEMBLY** 22034699 INSTALL SINGLE PORT VALVE KIT 14076388 INSTALL AIR BLEED KIT & 17085029 WASHER (AUTO TRANS ONLY) 11508426 CLAIM INFORMATION 4 22034699 V2835 .9

IMPORTANT: Submit a Product Campaign Claim based on the repairs performed and the labor information shown above plus the additional claim information shown below.

** REPLACEMENT OF PART NO. 22034699 REQUIRES CHEVROLET AREA SERVICE MANAGER APPROVAL.

Add .1 Others Hours to claim as 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 and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details an Product Campaign 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.