CAMPAIGN: HEATER OUTLET HOSE ASST. HOSE ROUTING/ABRASION. Buick Roadmaster 1992

For 1990-2009 cars

# CAMPAIGN: HEATER OUTLET HOSE ASST. HOSE ROUTING/ABRASION

#### SUBJECT: HEATER OUTLET HOSE ASSEMBLY ROUTING

#### MODELS AFFECTED: CERTAIN 1992 BUICK ROADMASTER ESTATE WAGONS

THIS IS A CUSTOMER SATISFACTION PRODUCT IMPROVEMENT CAMPAIGN.

#### DEFECT INVOLVED

General Motors has determined that certain 1992 Buick Roadmaster Estate Wagon model vehicles may have been built with the heater outlet hose routed above the heater inlet hose assembly allowing the heater inlet hose to contact the A.I.R. piping. This contact may cause the heater inlet hose to become damaged by either abrasion or heat.

#### DEALER ACTION

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the hose assembly, if necessary.

#### INVOLVED VEHICLES

Involved are certain 1992 Buick Roadmaster Estate Wagon model vehicles built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1992 Roadmaster Willow Run "W" NW402619 NW403025 Estate Wagon

Vehicles corrected at the assembly plant have been excluded from this campaign.

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 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 Buick 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 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 arrangements made to make the required correction according to instructions contained in this bulletin.

#### PARTS INFORMATION

Although most vehicles in this campaign will not require any parts to complete this campaign, a very small number of vehicles could experience a severely chafed and/or worn inlet hose. If a vehicle is found which requires a new inlet hose, order the appropriate replacement hose from your General Motors Parts and Illustration Guide.

DUE TO THE LIMITED NUMBER OF INLET HOSES AVAILABLE (AND TO ASSURE AVAILABILITY OF PARTS FOR VEHICLES WHICH EXPERIENCE A SEVERELY CHAFED OR WORN INLET HOSE) DO NOT ORDER AN INLET HOSE UNLESS YOU HAVE INSPECTED AND DETERMINED THAT A VEHICLE HAS A SEVERELY WORN OR CHAFED INLET HOSE.

#### SERVICE PROCEDURE

#### INSPECTION PROCEDURE

Determine if heater inlet hose is routed below heater outlet hose as shown in "INCORRECT" illustration.

If heater inlet hose is installed under heater outlet hose, "REROUTING PROCEDURE" below must be performed.

If heater inlet hose is routed as shown in "CORRECT" illustration, no further action is necessary. Install Campaign Identification Label and return vehicle to customer or to dealer stock.

#### REROUTING PROCEDURE

1. Park vehicle on a level surface.

2. Remove pressure cap from radiator when engine is cool by:

- Slowly rotating counterclockwise to detent. (Do not press down while rotating).

- Wait until any left-over pressure (indicated by a hissing sound) is released.

- After all hissing stops, press down on cap while continuing to rotate counterclockwise.

#### NOTICE: TO AVOID BEING BURNED, DO NOT REMOVE RADIATOR CAP WHILE ENGINE IS AT NORMAL OPERATING TEMPERATURE. COOLING SYSTEM WILL RELEASE SCALDING FLUID AND STEM UNDER PRESSURE IF CAP IS REMOVED WHILE ENGINE AND RADIATOR ARE STILL HOT.

3. With a clean drain pan in place, open radiator drain valve.

4. Once enough fluid has drained out of radiator:

- Remove screw from heater outlet hose bracket to cowl panel.

- Remove heater outlet hose from heater core tube (inboard tube) by squeezing both release tabs of quick connect fitting at base of heater core tube and pulling on pipe to disengage fitting (see quick connect fitting illustration).

5. Inspect inlet hose for signs of severe chafing and/or wear through (note that very few hoses are expected to be chafed or worn). If an inlet hose does require replacement, install new hose (P/N 10165021) following the procedures for the hose of the heater water control valve assembly on page 1B-26 of the 1992 Buick Roadmaster Service Manual.

6. Reposition outlet hose properly (under heater inlet hose), align orientation tabs with groves and push hose fitting in place then pull back on hose to ensure proper installation of connector.

#### NOTICE: Make sure two "O" rings and nylon spacers are in position in quick connect fitting prior to reinstalling outlet hose connection.

Also, make certain quick connect fitting orientation tabs are aligned correctly before connecting quick connect fitting. If quick connect fitting is incorrectly connected, coolant leakage and damage to parts may occur. The quick connect fitting must be pushed on, then pulled back to verify proper connector engagement.

Do not rely on an audible click or visual verification to check for a proper connection. If it is necessary to repair quick connect connector, use approved service kit which can be obtained from GMSPO. (P/N 10164697)

7. Install outlet hose bracket and screw to cowl panel.

8. Check outboard inlet hose for clearance to A.I.R. pipe. Also, check to assure protective sleeve on heater outlet hose is under heater inlet hose.

9. Close radiator drain valve.

10. Pour drained coolant into radiator until tank is filled.

11. Start engine and run five (5) minutes (or until inlet hose is hot).

12. Top off radiator with coolant and install cap.

13. Fill coolant recovery reservoir to hot line with coolant.

#### NOTICE: "Coolant" is 50/50 mix of water and ethylene glycol.

14. 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 space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a 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. Additional "Campaign Identification Labels" can be obtained from D.A.C.

Apply "Campaign Identification Label" only on a clean, dry surface.

#### DISPOSITION OF PARTS

Replaced parts must be held for disposition by Buick Zone or Branch contact personnel. Parts must have a claim tag attached showing the repair order and the VIN of the vehicle from which they are removed.

#### WARRANTY INFORMATION

FAILED OTHER SUBLET PART PART PART FAILURE LABOR LABOR LABOR DEALER OPER COUNT NUMBER ALLOW CODE OP.NO. HOURS HOURS MTL TWG ---- ----- ------ ----- ------- ------ ----- ----- ------- o Inspect/No Further Action Required

96 V7360 0.2 *0.1 --

o Inspect/Reroute Outlet Hose - Inlet Hose Not Chafed

96 V7361 0.4 *0.1 #

o Inspect/Reroute Outlet Hose - Replace Inlet Hose

10165021 *** 96 V7362 0.6 *0.1 #

* Campaign Administrative Allowance

** The "Parts Count" and "Failed Part Number" are dependent on need for service kit 10164697.

*** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair. Submit in the "Sublet Dealer Mtl Twg" column dealer cost plus 30% for one (1) pint of coolant required for Labor Operations V7361 and V7362.

Dear Buick Roadmaster Estate Wagon Owner:

We, at Buick Motor Division, are committed to improving the Buick customer ownership experience. We are writing you today to inform you of a customer satisfaction recall that includes your vehicle and our action to resolve this condition.

REASON FOR THIS RECALL

General Motors has determined that certain 1992 Buick Roadmaster Estate Wagon model vehicles may have been built with the heater outlet hose routed above the heater inlet hose assembly allowing the heater inlet hose to contact the Air Injection Reaction piping. This contact may cause the heater inlet hose to become damaged by either abrasion or heat.

WHAT WE WILL Do

To prevent this condition from occurring, dealers are to inspect for a properly routed heater outlet hose assembly and reroute the hose, if necessary. This service will be provided at no charge to you.

WHAT YOU SHOULD DO

Please contact your Buick dealer as soon as possible to arrange a service date. Instructions for making this inspection/correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

Your Buick dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. We suggest that you go to your selling or servicing dealer, but you may select any Buick dealer.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid 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.