CAMPAIGN: POWERMASTER BRAKE SYSTEM/FAULTY PRESSURE SWITCH. Pontiac Parisienne (Canada) 1986

For 1990-2009 cars

# CAMPAIGN: POWERMASTER BRAKE SYSTEM/FAULTY PRESSURE SWITCH

#### MODELS AFFECTED 1986 PARISIENNE WAGON

General Motors has determined that certain 1986 Pontiac Parisienne Station Wagons with Powermaster Brake Systems were built with combination valves and pressure switches which may become faulty. If left uncorrected these vehicles may experience a "hard brake pedal" or "increased brake pedal travel." These conditions may be caused by a Cast Iron combination valve allowing air to enter the brake system or by a pressure switch on the Powermaster Brake Assembly leaking brake fluid.

To prevent either of the above conditions from occurring, vehicles will be inspected and those equipped with the Cast Iron combination valve will receive a new Brass combination valve. Also, the pressure switch will be inspected and replaced, if necessary.

The intent of this Product Campaign is to preclude the unnecessary replacement of Powermaster Assemblies due to misdiagnosis of the conditions listed above. If a vehicle involved in this campaign appears to need additional repair or replacement of the Powermaster unit, refer to Dealer Technical Bulletin 86-5-22A for diagnosis procedures. Replacement of the complete Powermaster Assembly is NOT required to correct most customer concerns. Part kits are available that will resolve most concerns with this system, and eliminate unnecessary replacement of the complete Powermaster Assembly.

#### VEHICLES INVOLVED

Involved are certain 1986 Pontiac Parisienne Station Wagons with Powermaster Brake Systems built within the following VIN breakpoints: Up To And Year Plant Beginning Including ---- ------- --------- --------- 1986 Fairfax GX200005 GX285088

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identifica- tion 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 Pontiac 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 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 used vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

#### PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered on a C.I.O. order with no special instruction code, but on advise code (2).

Part Quantity Description Number Per Vehicle ----------------------------------- -------- ----------- Brass Combination Valve 25509419 1

Pressure Switch (Includes 2 O-Rings - one loose, one on Pressure Switch) 18018141 1

#### SERVICE PROCEDURE

1. Inspect pressure switch. If the current pressure switch terminal body is GRAY, move on to Step 2. If the current switch terminal body is BLACK, place a fender cover on the left fender, remove and replace pressure switch according to the procedure below and then move on to Step 2.

a. Depressurize the Powermaster unit by turning ignition "OFF," then apply and release brake pedal a minimum of ten (10) times using approximately fifty (50) pounds of force on pedal to fully deplete the power assist.

#### CAUTION:

Failure to fully depressurize the Powermaster unit could result in brake fluid being sprayed on service personnel and could cause damage to painted surfaces.

b. Disconnect the 3-wire electrical connector (Figure 1, 40) from pressure switch (Figure 1, 1).

c. Remove the old pressure switch (Figure 1, 1). The original O-ring should be on old pressure switch. If not, check Powermaster unit for the loose O-ring and remove it. Take care not to drip brake fluid on painted surfaces.

d. Obtain new pressure switch (P/N 18018141). The new pressure switch has on O-ring already installed in a groove on it. A second O-ring should be found loose in the box with the switch. Lubricate the second O-ring (Figure 1, 2) with clean, fresh brake fluid (DOT #3) and install in a groove between the threads and existing O-ring on the new pressure switch. The old pressure switch has only one O-ring. DO NOT reuse the old O-ring.

e. Install new pressure switch (Figure 1, 1) and torque to 24 N.m (18 lb.ft.).

#### NOTICE: Torque values specified are for dry, unlubricated fasteners.

f. Reconnect 3-wire electrical connector (Figure 1, 40) to pressure switch (Figure 1, 1). Be sure electrical connector is securely seated.

2. Locate combination valve (on frame rail below master cylinder). If the current combination valve is a Cast Iron valve, the valve must be replaced with a Brass valve by following the procedure below. If the vehicle already has the Brass valve, the combination valve does not need to be replaced. Proceed to Step 3. Figure 2 illustrates the differences in the two valve types.

a. Remove the electrical wiring harness connector from the pressure differential switch by squeezing the eliptical-shaped plastic lock ring and pulling up. A pair of pliers may aid in removing the connector.

b. Disconnect hydraulic lines at combination valve. Plug lines to prevent loss of fluid and entrance of dirt.

c. Remove cast iron combination valve.

d. Install Brass Combination Valve. Torque mounting bolts to 20 N.m (14 lb.ft.).

e. Remove plugs and connect hydraulic lines at combination valve. Torque lines to 24 N.m (18 lb. ft.).

f. Connect electrical wiring harness connector to pressure control differential switch.

g. Bleed entire brake system. Do not move vehicle until a firm brake pedal is obtained.

h. Check brake lines for leaks and proper clearances.

3. Install Campaign Identification Label.

#### 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 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 ball-point pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7901-709).

#### CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours ------------------------ ------- --------- ----- ----- Inspect Pressure Switch and Combination Valve - No Replacements Needed 96 V6160 0.2 0.1

Inspect Combination Valve & Pressure Switch - Replace Pressure Switch Only 96 V6161 0.4 0.1

Inspect Combination Valve & Pressure Switch - Replace Combination Valve Only 96 V6162 0.9 0.1

Inspect/Replace Combination Valve And Pressure Switch 96 V6163 1.2 0.1

Owner Reimbursement For Prior Replacement Of The Powermaster Brake Assembly, Combination Valve, And/Or Pressure Switch 95 T1640 --- ---

* In addition, dealerships will receive 0.1 hours credit for dealer adminis- trative 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.

#### FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

#### REIMBURSEMENT

Customer claims for reimbursement of prior replacement of the Powermaster Brake Assembly, Combination Valve, and/or Pressure Switch are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation listed under the Claim Information Section of this bulletin. Reimbursement amounts of $150.00 or less can be processed by the dealer. If the amount exceeds $150.00 an Owner Reimbursement Form 7201-039 (Rev. 6/88) must be forwarded to and processed by the Zone Office.

#### RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid. 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.

Dear Pontiac Owner:

This notice has been sent to inform you that Pontiac Division is conducting a recall campaign that includes your vehicle.

REASON FOR RECALL

General Motors has determined that 1986 Pontiac Parisienne Station Wagons with Powermaster Brake Systems were built with combination valves and pressure switches which may become faulty. If left uncorrected these vehicles may experience a "hard brake pedal" or "increased brake pedal travel." These conditions may be caused by a Cast Iron combination valve allowing air to enter the brake system or by a pressure switch on the Powermaster Brake Assembly leaking brake fluid.

WHAT WE WILL DO

To prevent either of the above conditions from occurring, vehicles will be inspected and those equipped with the Cast Iron combination valve will receive a new brass combination valve. Also, the pressure switch will be inspected and replaced, if necessary.

This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Pontiac 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, process and return your vehicle.

If your Parisienne Station Wagon has previously had the Powermaster Brake Assembly, combination valve and/or pressure switch replaced and you paid for all or part of the repair, you may request reimbursement through your Pontiac dealer. When doing so, you should present the dealer with documentation which reasonably confirms the amount of unreimbursed repair expense due to the replacement of the parts listed above, the date of the repair, and the person or entity performing the repair.

The enclosed Owner Identification Reply Card identifies your vehicle. Presen- tation 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.