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1990 Corvette: Recall: Instrument Panel Wire Abrasion - Repair

Subject: CAMPAIGN: INSTRUMENT PANEL WIRE ABRASION - REPAIR
Model and Year: 1990 CHEVROLET CORVETTE W/ L98 OR LT5 ENGINE
Source: Chevrolet Service Bulletin
Bulletin Number: 90-C-07 - (01/17/1990)

General Motors has determined that certain 1990 Chevrolet Corvette model vehicles with L98 or LT5 engines may experience instrument panel wires rubbing on the hood release cable bracket causing abrasion of the instrument panel wiring. If this condition continues to exist, the instrument panel wiring may wear through its covering and ground itself on the hood release cable bracket causing a short in the vehicle's electrical system and an inoperable vehicle engine.

In order to prevent the possibility of this condition occurring, dealers should apply 3M Brand, or equivalent, Electrical Moisture Sealant Tape to the instrument panel wiring and hood release cable bracket, thus protecting the instrument panel wires from abrasion. Additionally, instrument panel wiring which shows signs of abrasion should be repaired.

VEHICLES INVOLVED

Involved are certain 1990 Chevrolet Corvette model vehicles with L98 or LT5 engines built within the following VIN breakpoints:

MODEL/YEAR PLANT FROM THROUGH

---------- ----- ---- -------

Y 1990 Bowling Green L5100001 L5103172

Y 1990 Bowling Green L5800001 L5800227

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 Chevrolet Motor Division. Some owners will receive letters addressing more than one campaign on their vehicle (see copy of owner letters included with this bulletin) as shown in the chart below.

VIN Range Campaigns Addressed In Owner Letters

L5800001 -L5800120 90CO7 / 90CO9 / 9OC10 L5800121 -L5800213 90CO7 / 9OC10

L5800214 -L5800227 90CO7 L5100001 -L5100887 90CO7 / 90CO9

L5100888 -L5103172 90CO7

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

Parts required to complete this campaign are to be obtained from the dealer's 3M supplier (or equivalent material supplier).

Quantity/ Part Number Description Vehicle

----------- ------------ -------

06147 (3M Part #) 3M Brand Electrical approx. 2.5 ft. Moisture Sealant Tape (or equivalent)

SERVICE PROCEDURE

1. Remove left hand lower trim pad assembly, knee bolster pad, and A/C duct from drivers side of vehicle to gain access to instrument panel wiring harness (here after I/P harness).

2. Inspect I/P harness, at the point at which it routes past the hood release cable bracket, for any wire abrasion. If any wires are damaged, repair them using proper splicing techniques as described in Section 8A of the 1990 Corvette Service Manual.

3. Apply 3M Brand (or equivalent) Electrical Moisture Sealant Tape tightly to I/P harness for approximately 200mm (8 in.) starting at a point 150mm (6 in.) from bulkhead connector and continuing toward the cluster connector breakout (i.e. Cover I/P harness in area of the hood release cable bracket and clutch bracket).

NOTICE: Be sure to apply sealant tape only to clean/dry surfaces.

4. Apply sealant tape to hood release cable bracket to cover all sharp edges. Press tape tightly against bracket for good adhesion.

5. Reposition harness as far away from hood release cable bracket as possible and reinstall A/C duct, knee bolster pad and lower trim pad assembly.

6. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this bulletin will require a "Campaign Identification Label". Each label provides a space to include the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point 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 CC-FC LABOR LAB OTH NET REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS AMT ---------------- -- ------- ----- ------ -- ---- --- ---

Inspect and apply SK-00 V5710 0.6 0.1 $3.18 sealant tape

Inspect, repair SK-00 V5711 0.8 0.1 $3.18 wires and apply tape

* Campaign Administrative Allowance

** The $3.81 identified in the "Net Amount" column represents the cost plus 30% for 3M Brand Electrical Moisture Sealant Tape used in conjunction with labor operations V5710 & V5711.

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.

Dear Chevrolet Corvette ZR1 Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR THIS RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1990 Chevrolet Corvette ZR1 model vehicles. The fuel feed and return line connectors of these vehicles were built with the incorrect line end flare configuration. If these lines are left uncorrected, the line ends could crack causing a fuel leak which may result in an engine compartment fire.

Additionally, two other non-safety recalls will be performed on your vehicle while it is in for fuel line corrections. First, parking brakes on some 1990 Chevrolet Corvette ZR1s may become inoperable due to the cable button pulling through and separating from the nylon reel to which it is attached. This condition occurs on application only, not under sustained load conditions. The condition will be obvious due to a lack of resistance during parking brake application.

Finally, some 1990 Chevrolet Corvette ZR1s may experience instrument panel wires rubbing on the hood release cable bracket causing wire abrasion. If this condition continues to exist, the instrument panel wiring may wear through and ground itself on the hood release cable bracket, possibly causing a short in the vehicles electrical system and an inoperable vehicle engine.

WHAT WE WILL DO

To prevent the possibility of a fuel leak occurring, new fuel lines with the correct end flare configuration will be installed on the involved vehicles. Also, a new parking brake assembly will be installed, and protective electrical tape will be applied to the instrument panel wiring and hood release cable bracket, thus protecting the wires from abrasion. Additionally, instrument panel wiring which shows signs of abrasion will be repaired.

These services will be performed for you at no charge.

WHAT YOU SHOULD DO

Your authorized Chevrolet Corvette ZR1 Dealer will be contacting you soon to arrange a service date if it has not already done so. Instructions for making these corrections have been sent to this dealer along with parts to complete these repairs. The labor time to perform the necessary service corrections is approximately 2 hours. Your dealer can inform you of any additional time needed to schedule and process your vehicle.

Your authorized Chevrolet ZR1 Dealer is best equipped to obtain parts and provide service to insure that your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 366-0123).

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 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 safety and 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.

© Copyright General Motors Corporation. All Rights Reserved

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