CAMPAIGN: INJ. PUMP-GOVERNOR WEIGHT RETAINER ASSEMBLY

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN SOME EARLY PRODUCTION 1982 CUTLASS SUPREME, 88'S, 98'S AND TORONADOS EQUIPPED WITH 5.7L V-8 DIESEL ENGINES. UNDER CERTAIN VEHICLE OPERATING CONDITIONS THE GOVERNOR WEIGHT RETAINER IN THE INJECTION PUMP MAY FAIL AND THE THROTTLE VALVE COULD STICK, PREVENTING RETURN TO IDLE AND SHUT DOWN OF THE ENGINE BY THE OPERATOR OF VEHICLE. THIS COULD RESULT IN A LOSS OF VEHICLE CONTROL AND A VEHICLE CRASH COULD OCCUR WITHOUT PRIOR WARNING.

CARS AFFECTED

1982 CUTLASS, 88 98 AND TORONADO MODELS BUILT WITH A 5.7L V-8 DIESEL ENGINE FROM START OF PRODUCTION THROUGH THE FOLLOWING SERIAL NUMBERS.

LANSING CM 420273 CUTLASS SUPREME LINDEN CE311696 TORONADO

LANSING CM 162004-88-98 ST. THERESE C2349891 CUTLASS SUPREME

FAIRFAX CX105607 - 88

SOME VEHICLES WITHIN THE SERIAL NUMBERS LISTED MAY HAVE HAD THE CAMPAIGN CORRECTION PERFORMED IN THE ASSEMBLY PLANT BEFORE THE VEHICLE WAS SHIPPED. THESE CORRECTED VEHICLES CAN BE IDENTIFIED BY A RED "C" STICKER ON THE FRONT OF THE LEFT VALVE COVER, OR BY A DAUB OF RED PAINT ON THE PUMP TIMING BOSS.

DEALER ACTION

TO REDUCE THE POSSIBILITY OF THIS OCCURRING ON VEHICLES INVOLVED, THE FRIC- TION DRIVE GOVERNOR WEIGHT RETAINER ASSEMBLY IS TO BE REPLACED WITH A PELLETHANE GOVERNOR WEIGHT RETAINER ASSEMBLY, SEE FIG. 1.

DEALERS ARE TO PERFORM THIS RECALL CAMPAIGN AT NO CHARGE TO THE OWNER ON AFFECTED VEHICLES, REGARDLESS OF TIME, MILEAGE OR OWNERSHIP, AND ARE TO CORRECT ALL AFFECTED VEHICLES IN DEALER NEW AND USED CAR INVENTORY PRIOR TO THEIR SALE.

WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN INTO YOUR NEW OR USED CAR INVENTORY IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE BEFORE RESELLING THE VEHICLE.

DEALERS ARE TO PERFORM THE CAMPAIGN SERVICES ON ALL AFFECTED VEHICLES AS THEY ARE BROUGHT IN FOR ANY KIND OF SERVICE UNTIL ALL AFFECTED VEHICLES HAVE BEEN CORRECTED.

SERVICE PROCEDURE

A. INSPECTION ONLY:

IF THE VEHICLE SERIAL NUMBER FALLS WITHIN THE ABOVE RANGE OPEN THE HOOD AND LOCATE A RED "C" STICKER ON THE FRONT OF THE LEFT VALVE COVER OR A DAUB OF RED PAINT ON THE PUMP TIMING BOSS. IF EITHER OF THESE IDENTIFYING MARKS ARE LOCATED INSTALL A CAMPAIGN CORRECTION LABEL AS FOLLOWS: RECORD THE CAMPAIGN NUMBER 82-C-3 DEALER CODE AND DATE ON THE BLANK CAMPAIGN CORRECTION LABEL AND INSTALL ON THE RADIATOR BAFFLE WHERE IT IS READILY VISIBLE.

B. INSPECTION AND CORRECTION:

IF THE ABOVE DESCRIBED IDENTIFYING MARKS CANNOT BE LOCATED ON THE LEFT VALVE COVER OR ON THE PUMP TIMING BOSS THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED:

MANY DEALERS HAVE ATTENDED THE ADVANCE DIESEL CLASS OR HAVE OTHERWISE BEEN TRAINED TO CHANGE GOVERNOR WEIGHT RETAINER RINGS. THESE PROCEDURES ARE ALMOST IDENTICAL TO THE TRAINING YOU HAVE PREVIOUSLY RECEIVED HOWEVER, THERE ARE SOME CHANGES HIGHLIGHTED BY AN ASTERISK THAT NEED YOUR ATTENTION.

DEALERS SHOULD FOLLOW THE STEP BY STEP PROCEDURES. THERE ARE NO SPECIAL TOOLS REQUIRED HOWEVER, A PLATE TO MOUNT THE PUMP MAKES THE JOB CONSIDERABLY EASIER. WITHOUT THE PLATE, IT WILL TAKE 2 TECHNICIANS TO PERFORM SOME OF THE TASKS. NO ATTEMPT WHATSOEVER SHOULD BE MADE TO MOUNT THE PUMP IN A VISE. A TEMPLATE SHOWING A PUMP MOUNTING PLATE IS INCLUDED IN THE EVENT YOU SHOULD WISH TO HAVE ONE MADE. (SEE FIG. 2). MOUNTING PLATES ARE AVAILABLE FROM KENT MOORE (TOOL NUMBER J29692A) AND BORROUGHS TOOL AND EQUIPMENT CO. (TOOL NUMBER BT-8046 OR BT-8046P).

THE DIESEL INJECTION PUMP IS A COMPLEX ITEM, CONTAINING CLOSE TOLERANCE PIECES. CLEANLINESS IS ESSENTIAL. YOUR TOOLS AND WORK AREA MUST BE CLEAN. INJECTION PUMP PARTS SHOULD BE PLACED IN CLEAN METAL TRAYS ONLY.

DISASSEMBLY

1. OBSERVE POSITION OF TIMING ALIGNMENT MARKS SO PUMP CAN BE REINSTALLED IN SAME POSITION. REMOVE THE INJECTION PUMP FROM THE VEHICLE FOLLOWING THE PROCEDURE OUTLINED IN SECTION 8C5 OF THE 1982 CHASSIS SERVICE MANUAL AND PAGE 6 OF THE OCTOBER 1982 SERVICE GUILD.

2. SCRIBE A LINE ON THE VACUUM REGULATOR VALVE AND PUMP BODY SO THE VALVE CAN BE REINSTALLED WITHOU RESETTING. REMOVE THE VALVE.

3. INSTALL PLUGS IN THE DISCHARGE PROTS, FUEL INLET PORT AND RETURN LINE PORT. CLEAN THE PUMP THOROUGHLY ON THE OUTSIDE. ANY CLEANER THAT DOES NOT IRRITATE THE SKIN SHOULD BE SATISFACTORY. IF NOTHING ELSE IMMERSE IN DIESEL FUEL, BRUSH CLEAN AND BLOW DRY.

4. INSTALL THE PUMP IN A HOLDING FIXTURE SO THAT REAR OF PUMP IS TILTED DOWNWARD. SEE FIG. 11.

5. REMOVE THE THREE GOVERNOR COVER SCREWS AND REMOVE THE COVER. REFER TO FIG 3. CATCH DIESEL FUEL IN DRAIN PAN WHEN COVER IS REMOVED.

6. REMOVE THE GUIDE STUD AND GUIDE STUD WASHER. REMOVE THE MIN/MAX GOVERNOR ASSEMBLY. SEE FIGS. 4 AND 5. IF GUIDE STUD WASHER HAS A RUBBER INSERT IN IT, DO NOT DISCARD, IF IT IS A SOLID ALUMINUM TYPE, DISCARD.

7. INSTALL TOOL J-29601 ON THE THROTTLE SHAFT AND TIGHTEN THUMB SCREW. REMOVE THE TOOL SEE FIG. 6.

NOTE: THIS SETTING IS USED TO POSITION ADVANCE CAM DURING REASSEMBLY.

8. REMOVE THE VACUUM REGULATOR VALVE DRIVE PIN AND CAM SCREW. REMOVE THE THROTTLE SHAFT AND ADVANCE CAM. SEE FIG. 7.

9. REMOVE THE GOVERNOR LINKAGE ASSEMBLY AND THE METERING VALVE. SEE FIG. 8.

10. USING A 1/8" ALLEN WRENCH REMOVE THE HOUSING VENT SCREW. REFER TO FIG. 9.

11. REMOVE ONE HEAD LOCKING SCREW AND LOOSEN THE OTHER, TURN PUMP UPSIDE DOWN AND REMOVE THE HEAD LOCATING SCREW. SEE FIG. 10.

12. REMOVE THE ADVANCE SCREW HOLE PLUG, LIFT OUT THE CAM ADVANCE PIN, USING A PAIR OF NEEDLE NOSE PLIERS. SEE FIG. 11.

13. ROTATE THE PUMP UPRIGHT AND REMOVE ONE REMAINING HEAD LOCKING SCREW. REMOVE THE HEAD AND ROTOR ASSEMBLY FROM THE PUMP HOUSING BY GRASPING THE HEAD WITH BOTH HANDS AND ROTATING BACK AND FORTH WHILE PULLING. REFER TO FIG. 12.

14. REMOVE THE GOVERNOR WEIGHTS, THRUST SLEEVE AND THRUST WASHER AND REMOVE THE SNAP RING. REMOVE THE GOVERNOR WEIGHT RETAINER ASSEMBLY. SEE FIGS. 13 AND 14.

NOTE: DO NOT REMOVE ANY OTHER PARTS FROM THE HEAD AND ROTOR.

ASSEMBLY

1. REMOVE OLD HYDRAULIC HEAD SEAL AND INSTALL A NEW HYDRAULIC HEAD SEAL PROVIDED IN KIT. SEE FIG. 12 FOR LOCATION OF HEAD SEAL.

2. INSTALL THE NEW GOVERNOR WEIGHT RETAINER ASSEMBLY PROVIDED IN THE KIT.

3. INSTALL GOVERNOR WEIGHT RETAINER SNAP RING.

4. WITH HEAD AND ROTOR ASSEMBLY STANDING UPRIGHT ON WORK BENCH, INSTALL GOVERNOR WEIGHTS AND THRUST WASHER IN CAGE. MAKE SURE WASHER IS POSITIONED IN SLOTS OF EACH GOVERNOR WEIGHT. SEE FIG. 15.

5. POSITION THRUST SLEEVE ON TOP OF THRUST WASHER.

6. APPLY A COAT OF GREASE FROM GREASE PACK IN KIT TO THE HYDRAULIC HEAD SEAL.

*7. LOCATE THE TOP OF THE HEAD AND ROTOR BY FINDING THE TRANSFER PUMP TAP SCREW. SEE FIG. 10. ROTATE THE CAM RING UNTIL THE SMALLEST HOLE IS AT THE BOTTOM. NOTE: THE THREADS OF A HEAD LOCKING SCREW WILL NOT FIT INTO THE SMALLEST CAM RING HOLE.

8. ROTATE THE DRIVE SHAFT UNTIL THE "T" MARK IS POSITIONED UPWARD. SEE FIG. 16. OBSERVE THE DOT ON THE OPPOSITE END OF THE DRIVE SHAFT TANG, AND LOCATE THE DOT IN THE DRIVE SHAFT SLOT. HOLD THE CAM RING AND ROTATE THE RETAINER TO ALIGN THE DOTS. SEE FIG. 17.

9. INSERT THE HEAD AND ROTOR ASSEMBLY INTO THE HOUSING. ROTATE THE DRIVE SHAFT BACK AND FORTH SLIGHTLY UNTIL IT IS ENGAGED. COMPLETE THE IN- SERTION OF THE HEAD AND ROTOR INTO THE HOUSING USING A TWISTING MOTION UNTIL THE HEAD LOCKING SCREW HOLES LINE UP.

NOTICE: INSERTION OF THE HEAD TOO FAR INTO THE PUMP MAY CUT THE HOUSING SEAL. IF THE HEAD GOES IN FURTHER THAN THE LOCATING SCREW HOLES CHECK THE HOUSING TO SEE IF SEAL IS EXPOSED IN THE OPENING FOR THE VENT SCREW, IF IT IS, REMOVE AND REPLACE THE SEAL.

10. RETAIN THE HEAD AND ROTOR ASSEMBLY INTO THE HOUSING BY INSTALLING THE TWO (2) HEAD LOCKING SCREWS (HAND TIGHT). REFER TO FIG. 10.

11. TURN PUMP UPSIDE DOWN AND INSTALL HEAD LOCATING SCREW USING A NEW HEAD LOCATING SCREW SEAL. TORQUE LOCATING SCREW TO 24.4 N.M (17 FT.LBS.); THEN TORQUE THE TWO (2) HEAD LOCKING SCREWS TO 24.4 N.M.(17 FT. LBS.).

12. INSTALL CAM PIN USING NEEDLE NOSE PLIERS. REFER TO FIG. 11. NOTE: WITH A SMALL SCREWDRIVER, LINE UP THE HOLE IN THE POSITION AND CAM RING. MOVE THE SERVO PISTON OUT OF THE WAY.

13. INSTALL ADVANCE PIN HOLE PLUG. TORQUE TO 10.8 N.M (8 FT. LBS.)

14. TURN PUMP RIGHT SIDE UP AND REMOVE THE TIMING LINE COVER AND GASKET. SEE FIG. 18.

*15.CHECK INTERNAL PUMP TIMING BY VIEWING THROUGH THE TIMING LINE OPENING. THE LINE ON THE CAM RING SHOULD BE VISIBLE. USING A FLASHLIGHT, ROTATE THE DRIVE SHAFT UNTIL THE HEAD OF A SCREW IS VISIBLE IN CAM RING. (ALLEN HEAD) THE "T" ON THE DRIVE SHAFT SHOULD BE POSITIONED DOWNWARD IF PROPERLY TIMED. IF BOTH CONDITIONS ARE NOT MET, THE CAM RING OR THE HEAD COULD BE INSTALLED IMPROPERLY. DISASSEMBLE AND CORRECT. REFER TO FIG. 18.

16. INSTALL TIMING LINE COVER.

17. INSTALL HOUSING VENT SCREW AND METERING VALVE. REFER TO FIG. 8.

18. ROTATE THRUST SLEEVE SO THAT FLAT ON SLEEVE IS UP.

19. INSTALL PIVOT ARM AND LINKAGE HOOK ASSEMBLY MAKING SURE THE FEET ON THE PIVOT ARE FORWARD OF THE THRUST SLEEVE.

20. ROTATE THE METERING VALVE BACK AND FORTH; THE LINKAGE SHOULD NOT RESTRICT THE MOVEMENT OF THE VALVE.

21. POSITION ADVANCE CAM BETWEEN ADVANCE LEVER ARM AND HOUSING MAKING SURE THAT MYLAR WASHER IS IN POSITION ON THE CAM. SEE FIG. 19.

22. USING NEW THROTTLE SHAFT SEALS LUBRICATE SEALS AND SHAFT AND INSTALL THROTTLE SHAFT INTO HOUSING AND ADVANCE CAM.

23. INSTALL ADVANCE CAM SCREW (HAND TIGHT.)

24. INSTALL NEW THROTTLE SHAFT DRIVE PIN PROVIDED IN KIT.

25. INSTALL TOOL J-29601 ON THROTTLE SHAFT OVER DRIVE PIN TO PROPERLY ALIGN CAM. REFER TO FIG. 6.

26. INSERT A .005 FEELER GAUGE BETWEEN THE WHITE WASHER ON THE THROTTLE SHAFT AND THE PUMP HOUSING. SQUEEZE THE CAM AND THROTTLE SHAFT TOGETHER AND TIGHTEN THE CAM SCREW. TORQUE TO 3.4 N.M (30 IN. LBS.). SECURE WITH LOCTITE 290. REMOVE TOOL J-29601. REFER TO FIG. 20.

27. PIVOT THE MIN/MAX GOVERNOR ASSEMBLY INTO POSITION. REFER TO FIG. 5.

28. INSTALL THE GUIDE STUD AND NEW GUIDE STUD WASHER IF NEEDED, MAKING CERTAIN THAT THE UPPER EXTENSION OF THE METERING VALVE SPRING RIDES ON TOP OF THE GUIDE STUD. TORQUE THE GUIDE STUD TO 9.5 N.M (7 FT.LBS.) DO NOT OVERTORQUE THE GUIDE STUD.

29. INSTALL A NEW PUMP COVER GASKET ON THE COVER. MAKE SURE THE SCREWS ARE NOT IN THE COVER AND POSITION THE COVER ABOUT 1/4 INCH FORWARD (TOWARD SHAFT END) AND ABOUT 1/8 INCH ABOVE THE PUMP.

30. MOVE THE COVER REARWARD AND DOWNWARD INTO POSITION, BEING CAREFUL NOT TO CUT THE GASKET AND REINSTALL THE COVER SCREWS. BE CAREFUL NOT TO DROP FLAT WASHER AND INTERNAL LOCK WASHER WITH EACH SCREW. FLAT WASHER MUST BE AGAINST PUMP COVER. TORQUE TO 3.5 N.M. (33 IN LBS.)

31. TO PRESSURE TEST, FOLLOW THE PROCEDURE ON PAGE 6C5-13 OF THE 1982 CHASSIS SERVICE MANUAL. IF NO LEAKS ARE OBSERVED CONTINUE WITH STEP 32.

32. REINSTALL VACUUM REGULATOR VALVE ON PUMP, LINING UP VALVE TO SCRIBE MARK MADE IN STEP 4 OF DISASSEMBLY. TORQUE BOLTS TO 5.4 N.M (4 FT.LBS.) REINSTALL PUMP IN VEHICLE FOLLOWING THE PROCEDURE IN SECTION 6C5 OF THE 1982 CHASSIS SERVICE MANUAL AND PAGE 6 OF THE OCTOBER 1981 SERVICE GUILD. TIMING ALIGNMENT MARKS SHOULD BE ALIGNED IN SAME POSITION NOTED IN STEP 1 OF DISASSEMBLY. NOTE: DO NOT START THE ENGINE UNTIL STEPS 33 AND 34 HAVE BEEN COMPLETED.

33. AFTER PUMP IS REINSTALLED IN THE VEHICLE TURN THE IGNITION SWITCH TO THE RUN POSITION AND TOUCH THE PINK FUEL SOLENOID WIRE TO THE SOLENOID. A CLICKING NOISE SHOULD BE HEARD AS THE WIRE IS CONNECTED AND DISCONNECTED. IF THIS CLICKING IS NOT OBSERVED, THE LINKAGE MAY BE JAMED IN A WIDE OPEN THROTTLE POSITION AND THE ENGINE MUST NOT BE STARTED. IF CLICKING IS OBSERVED CONNECT THE ELECTRICAL CONNECTOR(S) THEN PROCEED TO STEP 35.

34. IF CLICKING IS NOT OBSERVED REMOVE THE COVER. GROUND THE SOLENOID LEAD (OPPOSITE THE HOT LEAD) AND CONNECT THE PINK WIRE. WITH THE IGNITION SWITCH IN THE RUN POSITION, THE SOLENOID IN THE COVER SHOULD MOVE THE LINKAGE. IF NOT, THE SOLENOID MUST BE REPLACED. MINIMUM VOLTAGE ACROSS SOLENOID TERMINALS MUST BE 12.0 VOLTS.

35. START THE ENGINE AND CHECK FOR LEAKS. (USING A JUMPER TO ENERGIZE THE HOUSING PRESSURE COLD ADVANCE SOLENOID WILL REDUCE STARTING TIME.)

36. IDLE ROUGHNESS MAY BE OBSERVED DUE TO THE AIR IN THE PUMP, GIVE IT PLENTY OF TIME TO PURGE WHICH IT WILL DO BY ALLOWING THE ENGINE TO IDLE. IT MAY BE NECESSARY TO SHUT THE ENGINE DOWN FOR SEVERAL MINUTES TO ALLOW AIR BUBBLES TO RISE TO THE TOP OF THE PUMP WHERE THEY WILL BE PURGED.

37. USING MAG TAC (J-26925), SET IDLE SPEEDS ACCORDING TO EMISSION LABEL.

38. AFTER THE ABOVE HAS BEEN COMPLETED INSTALL A CAMPAIGN CORRECTION LABEL AS FOLLOWS: RECORD THE CAMPAIGN NUMBER 82-C-3, DEALER CODE AND DATE ON THE BLANK CAMPAIGN CORRECTION LABEL AND INSTALL ON THE RADIATOR BAFFLE WHERE IT IS READILY VISIBLE.

PARTS INFORMATION

THE PARTS REQUIRED FOR THIS CAMPAIGN ARE AVAILABLE THROUGH GM PARTS (WDDGM)

PART NUMBER 22518269 GOVERNOR WEIGHT RETAINER ASSEMBLY KIT

TO INSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE THEY SHOULD BE ORDERED FROM GM PARTS (WDDGM) ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2).

THE GOVERNOR WEIGHT RETAINER ASSEMBLY AND PARTS ARE TO BE RETAINED FOR DISPOSITION BY ZONE PERSONNEL.

WARRANTY CLAIM INFORMATION

ALL DEALERS NOT USING THE TERMINAL SUBMISSION SYSTEM ARE TO SUBMIT CAMPAIGN CLAIMS USING THE "YELLOW STRIPE" CAMPAIGN CARDS.

ALL DEALERS USING THE TERMINAL SUBMISSION SYSTEM ARE TO SUBMIT CAMPAIGN CLAIMS USING THEIR TERMINAL. SEE PAGE 59 OF THE OLDSMOBILE CLAIMS PREPARA- TION MANUAL.

OPERATION OPERATION NO. LABOR

INSPECTION ONLY V1100 .2 HR. R & R PUMP AND REPLACE V1101 2.0 HR GOVERNOR ASSEMBLY

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.