CAMPAIGN: BATTERY LEAKAGE- REPLACE HEAVY DUTY BATTERY

MODELS AFFECTED: 1985 ELECTRAS EQUIPPED WITH HEAVY DUTY BATTERIES

General Motors has determined that some 1985 Electra Coupes and Sedans were assembled with batteries that may leak acid. This acid may cause possible degradation of the transmission cooler hoses and other components in the area of the battery.

To prevent these conditions from occurring on vehicles involved, dealers are to determine if the vehicle is equipped with original equipment battery number 107 or aftermarket number 78A-60. If the vehicle is equipped with one of these batteries, they will be replaced with a new 78A-72 battery, the transmission cooler hoses will be replaced, and any other battery acid affected component will be cleaned or replaced.

VEHICLE INVOLVED

Certain 1985 Electra Coupes and Sedans with 3.0L and 3.8L engines and 107 or 78A-60 heavy duty batteries (UAI option) within the following VIN breakpoints:

PLANT FROM TO AND INCLUDING ----- ---- ----------------- Wentzville F1 400126 F1 425364

SOME OF THE VEHICLES WITHIN THESE BREAKPOINTS WILL NOT REQUIRE BATTERY REPLACEMENT AS THEY WERE NOT ASSEMBLED WITH A HEAVY-DUTY BATTERY.

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 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 before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangemerits made to make the required modification according to instructions contained in this bulletin.

DEALER MATERIAL

If your dealership has vehicles involved in this campaign, you will receive the following items:

List of all vehicles involved in this campaign shipped to your dealership.

One campaign identification label for each vehicle.

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.

TRANSFER OF VEHICLE

If a vehicle has been transferred or sold to another location, please forward vehicle information for this vehicle to your Buick Zone Office for handling with the proper dealer.

OWNER NOTIFICATION

Owners of vehicles involved in this campaign will be notified by Buick Motor Division (see copy of Owner letters included with this bulletin).

CHANGE OF OWNER INFORMATION

Dealers are to use the Dealer Communication System (D.C.S.) to provide Buick Motor Division with subsequent Buick owner information. By reporting a change of owner name or address of a vehicle in campaign status over the D.C.S., the need to send in a C.V.A.R. Form for that vehicle is eliminated. Terminal input instructions are covered in the D.C.S. Manual under Section 9, page 9-JO1A and B.

PART INFORMATION

The batteries for this campaign are to be obtained from your local AC-Delco outlet. One 78A-72, part number 1981590, is required for each vehicle that requires a battery replacement. The other parts for this campaign are to be obtained from GMWDD as follows:

Description Part Number Number Per Vehicle ----------- ----------- --------------------- Kit, Transmission Cooler 1 for each vehicle Hoses & Clamps 25526686 with 107 or 78A-60 battery

Hood Release Cable 20470537 As Required Power Steering Cooler Pipe Package 22527846 As Required Washer Hose 5/. 92" 1359744 (25 Ft. Roll) As Required

Upper Radiator Hose 3.8L Engine 25516661 As Required 3.OL Engine 25515308 As Required

FOR ADDITIONAL PARTS THAT MAY BE REQUIRED, REFER TO THE 1985 BUICK "C" CAR PARTS AND ILLUSTRATION CATALOG.

To ensure that 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).

SPECIAL MATERIALS

The following material is required for cleaning acid affected parts:

Sodium Bicarbonate (Baking Soda) Purchase Locally

TECHNICAL PROCEDURE

PART A - INSPECTION OF BATTERY

1. Open vehicle hood, cover fenders, and inspect "Caution" label on top surface of battery. Refer to Figure 1.

a. Replace batteries identified as original equipment number "107" or after market (replacement) number "78A-60" on "Caution" label following the complete procedure in PART B of this procedure.

b. DO NOT replace batteries that are not identified as described in Step "a" above, as no further action is required, except to install a campaign identification label, PART C of this procedure.

PART B - COMPONENT INSPECTION, CLEANING, REPAIR AND REPLACEMENT

CAUTION:

FOLLOW RECOMMENDED PRECAUTIONS IN HANDLING BATTERIES AND POTENTIAL BATTERY ACID CONTAMINATION COMPONENTS. BATTERY ACID IS CORROSIVE. PROPER PROTECTIVE CLOTHING AND SAFETY GLASSES SHOULD BE WORN DURING THE FOLLOWING WORK:

1. Disconnect battery negative cable, positive cable, remove retainer screw and retainer. Carefully remove battery, tag with vehicle information, and store in a safe area for disposition.

2. Inspect the following areas for evidence of battery acid. Make note of areas where acid or acid residue is present. Acid residue can usually be identified as a whitish discoloration or deposit. Acid can result in corrosion or paint peeling on metals and softening and blistering of rubber and certain plastic compounds.

a. Battery tray, holddown bolt, and plastic clamp,

b. Left inner fender area,

c. Left shock tower,

d. Left horns,

e. Radiator,

f. Lower radiator support,

g. Transmission oil cooler lines, hoses, and clamps,

h. Power steering oil cooler lines, hold down bracket and bolt,

i. Hood release cable,

j. Windshield washer hose,

k. Upper radiator hose and clamp at radiator,

l. Air cleaner housing and inlet area (3.8L engine only),

m. Hood insulation above battery,

n. Engine cradle under battery,

o. Side rail under battery,

p. Any other suspected contaminated part in battery area.

3. If there were no evidence of battery acid found in Step 2, proceed to Step 5 of this procedure to replace transmission cooler hoses and install new battery. If evidence of acid presence was noted in Step 2, clean affected parts and areas using the following procedure:

a. Purchase sodium bicarbonate (baking soda) locally.

b. Sprinkle affected area with baking soda.

c. Mix a solution of one (1) part baking soda by volume to one (1) part water.

d. Brush affected parts and areas liberally with solution, making sure to cover all surfaces.

e. Let stand until affected area stops gassing (foaming).

f. Rinse with clean water.

g. Repeat application five (5) times and rinse.

4. After neutralizing acid in Step 3, proceed to correct possible degradation, as listed below. Perform only the appropriate steps listed where acid presence was noted:

STANDARD PAINT REFINISH PROCEDURES SHOULD BE USED WHEN REPAIRING PAINT THAT WAS DAMAGED BY BATTERY ACID.

a. Power Steering Oil Cooler Lines

Place container under line connections. Remove old lines. Clean holddown bracket, attaching screw, lower radiator support behind holddown bracket and along side rail where lines were, with baking soda and water solution. Replace power steering oil cooler line with package number 22527846,Refer to Figure 2. Fill power steering system to replace lost fluid.

b. Battery Tray, Holddown Bolt and Plastic Clamp

Make sure acid residue has been thoroughly cleaned. Repaint tray as required.

c. Lower Radiator Support and Radiator

Make sure acid residue has been thoroughly cleaned. Repaint affected areas as required.

d. Upper Radiator Hose and Clamp at Radiator

Remove hose and replace clamp at radiator. Install new hose and clamp at radiator. Fill radiator with recommended coolant. Torque clamps to 2.0 N.m. (18 lb. in.).

e. Windshield Washer Container Hose and Hood Release Cable

Replace washer container hose with service part number 1359744 cut to proper length. Replace hood release cable.

f. Other Parts and Areas

Work performed and time allowance in the following areas must have zone approval:

(1.) Left inner fender area,

(2.) Left shock tower,

(3.) Left horns,

(4.) Air cleaner housing and inlet area,

(5.) Hood insulation above battery. If battery acid is evidenced on hood insulator, it should be replaced and inner hood panel should be cleaned and paint repaired, if required.

(6.) Engine cradle under battery,

(7.) Other suspected contaminated parts in battery area.

5. Place drain container under transmission cooler hoses.

6. Remove transmission cooler hoses. If required, clean end of lines with a clean rag soaked in the baking soda and water solution; cover ends of lines with tape and repaint affected areas. Remove tape. Install new hoses and clamps using parts in Kit 25526686. Refer to Figure 3. Torque clamps to 1.5 N.m (13 lb. in.).

7. Measure transmission oil lost during hose replacement and install same amount of new oil in transmission.

8. Install new service battery 78A-72, part number 1981590. Tighten battery retainer screw to 17 N.m (13 lbs. ft.). Connect, positive cable, negative cable, and tighten cable bolts to 12 N.m (9 lbs. ft.).

9. Start engine and check for leaks at cooler hose connections, and at connections of other replaced fluid lines and hoses. Repair, if required.

PART C - CAMPAIGN I.D. LABEL INSTALLATION ----------------------------------------- Install a Campaign Identification label. Each vehicle modified in accordance with the instruction 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 support and apply the campaign label where it is readily visible.

DISPOSITION OF REPLACED PARTS

All replaced parts must be held for disposition by Buick contact personnel. Each replaced part must have a claim tag attached showing the repair order and the VIN of the vehicle from which it was removed.

WARRANTY INFORMATION

Dealers are to submit each campaigned vehicle as a separate case on the one-line warranty document form S-764. Dealers submitting warranty claims by teletype terminal are to transmit campaign completions as a separate case also.

LIST THE ONE APPLICABLE LABOR OPERATION

SUBLET PART FAILED PARTS FAILURE LABOR LABOR *OTHER DEALER OPER. COUNT PART NO. ALLOW. CODE OP. NO. HOURS HOURS MTL.TWG.

Inspect Battery Only -- -- -- 96 V2660 .2 .1 +++

Inspect, Replace Battery and Transmission Cooler Hoses. 2 1981590 ++ 96 V2661 .5 .1 +++

Same as Oper. # V2661 plus Clean-up Components 2 1981590 ++ 96 V2662 .9 .1 +++ TEXT ZONE

Same as Oper.# V2662 plus Replace Power Steering Cooler Pipe 3 1981590 ++ 96 V2663 1.3 .1 +++

* .1 hour for Administration.

++ List current dealer price plus 30% of parts replaced less scrap allowance of $1.95 for replaced battery.

+++ List amount for items required such as sodium bicarbonate (baking soda), Fluids (Power Steering, Transmission, Engine Coolant), Paint, and Washer Hose.

NOTE: Add to applicable above labor hours, as required.

Replace washer hose = .1 hr.

Replace upper radiator hose = .2 hr.

Recoat affected parts = .6 hr. (Radiator support, radiator, battery tray).

Replace hood release cable = .3 hr.

THE FOLLOWING LABOR OPERATION IS ONLY TO BE USED WHEN ADDITIONAL PARTS AND/OR LABOR ARE REQUIRED AND ZONE AUTHORIZATION HAS BEEN OBTAINED.

SUBLET PART FAILED PARTS FAILURE LABOR LABOR *OTHER DEALER OPERATION COUNT PART NO. ALLOW. CODE OP. NO. HOURS HOURS MTL TWG

0 Includes all items. in oper V2663 plus additional parts and/or labor authorized by Zone. x 1981590 xx 96 V2664 xxx .1 hr. xxxx

* .1 hr. for administration.

x List number of parts replaced.

xx List current dealer price plus 30% of all parts replaced less scrap allowance of $1.95 for replaced battery.

xxx List labor time authorized (includes total time allowed for oper. V2663, plus additional time authorized to complete repairs).

xxxx List amount for items required, such as sodium bicarbonate (baking soda), fluids, (power steering, transmission, engine coolant), paint and washer hose.

To assure accurate records of all transactions on this campaign, it is recommended that campaign repairs for each vehicle be listed on a separate repair order. Other repairs performed to the vehicle may be listed on the same repair order, and warranty cases other than campaigns may be listed on the same warranty document.

Dear Buick Owner:

General Motors has determined that some 1985 Electra Coupes and Sedans were assembled with batteries that may leak acid. This acid may cause possible degradation of the transmission cooler hoses and other components in the area of the battery.

To prevent these conditions from occurring on your vehicle, your Buick dealer will determine if the vehicle is equipped with an original equipment 107 or replacement 78A-60 battery. If the vehicle is equipped with one of these batteries, they will be replaced with a new 78A-72 battery, the transmission cooler hoses will be replaced and any other battery acid affected component will be cleaned or replaced. This service will be done at no charge to you.

Instructions for making this correction have been sent to your Buick Dealer. Parts will be available approximately May 1, 1985. Please contact your dealer after this date to arrange a service date to have your vehicle corrected. The labor time to inspect your vehicle is approximately five minutes. If the battery and transmission cooler lines are replaced, the labor time is approximately twenty minutes. If additional clean-up or replacement of other components are required, labor time will be increased accordingly. Please ask your dealer if you wish to know how much additional time will be necessary to process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the 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.

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.