Technical Procedure

FIGURE 1 - CAUTION LABELS USED ON BATTERIES TO BE REPLACED:

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 aftermarket (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 OURING 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 or 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, 1. 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.

FIGURE 2 - POWER STEERING COOLER PIPE INSTALLATION:

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 in. lbs.).

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.

FIGURE 3 - TRANSMISSION COOLER LINE HOSE INSTALLATION:

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 in.lbs.).

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 ft.lbs.). Connect, positive cable, negative cable, and tighten cable bolts to 12 N-m (9 ft.lbs.).

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

CAMPAIGN I.D. LABEL:

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.