CAMPAIGN: LEFT FRONT BRAKE PIPE INTERFERENCE. Buick Regal 1996

Subject: LEFT FRONT BRAKE PIPE INTERFERENCE ----------------------------------

Models: 1996 Buick Regal (RPO JL9) with ABS Brakes ------------------------------------------

TO: ALL GENERAL MOTORS DEALERS

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General Motors of Canada Limited has decided that a defect which relates to motor vehicle safety exists in CERTAIN 1996 Buick Regal model vehicles. The left front brake line on some of these vehicles may be contacting the transaxle mounting bracket or attachment bolt. This condition can cause the brake line to wear through, resulting in loss of brake fluid and eventual loss of one half of the vehicle braking system.

If this condition were to occur in a situation where stopping distances were minimal, a vehicle crash could occur without prior warning.

To prevent the possibility of this condition occurring, dealers are to inspect for proper brake line clearance and reposition those brake lines found to have less than minimal clearance. Additionally, those brake lines found to have an indentation caused by the contact will be replaced and properly routed.

VEHICLES INVOLVED:

Involved are CERTAIN 1996 Buick Regal model vehicles built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- --------

1996 Buick Regal Oshawa #2 1 SOP T1429890

NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEAlER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

IT IS ANTICIPATED THAT APPROXIMATELY 5% OF ASSIGNED UNITS WILL REQUIRE BRAKE LINE REPLACEMENT FOR THIS CONDITION. THEREFORE, PLEASE DO NOT ORDER PARTS FOR SHELF STOCK. ONLY ORDER PARTS IF TRULY IN NEED.

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 10152241 Brake Pipe, Left Front As Required 992669 Brake Fluid As Required

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- --------------

IA Inspect Left Front Brake Line For Proper 0.4 Clearance & Clip Retention - Reposition as Necessary

2A Inspect Left Front Brake Line - 0.7 Replace Left Front Brake Line

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus appropriate model year parts handling allowance. An allowance of $1.50 is included in repair code 2A for brake fluid.

SERVICE PROCEDURE:

1. Turn steering wheel to full right position.

2. Raise vehicle.

3. Inspect left front brake line at transaxle mount bracket and attachment bolt for proper clearance and proper clip position (see Figure on Page 4).

4. If clearance is greater than 13mm or (1/2') or greater for the clip and the line, DO NOT reposition line. Ensure lines are properly secured in clip and clip is in proper location (proceed to Step #1 1).

LACK OF CLEARANCE

5. If clearance is found to be less than the minimum of 13mm or (1/2"), or line is out of clip, inspect line to determine if contact has been occurring with the transaxle bracket and/or attachment bolt.

A. If no contact was made or the line only appears shiny (polished), it will only be necessary to reposition the line and ensure proper clip retention (proceed to Step #6).

B. If an indentation was worn into the line it will be necessary to replace the line (proceed to Step #7).

If the contact has resulted in an indentation in the surface of the line that can be felt with a fingernail or screwdriver edge, the brake pipe needs to be replaced.

6. Reposition brake line by hand (it may be necessary to remove spacer clip prior to reposition) to ensure that line and clip clearance is greater than 13mm or (1/2") from transaxle bracket and attachment bolt or other sharp edges (proceed to Step #11).

LINE REPLACEMENT

7. Remove left front brake line from the brake hose at the retainer, and from the ABS Hydraulic Modulator/Master Cylinder.

8. Install NEW left front brake line. Ensure clearance is greater than 13mm (1/2") for line and clip.

9. Tighten brake line fitting to ABS Hydraulic Modulator/Master Cylinder to 24 N.m (I 8 lb. ft.) and brake line fitting to brake hose fitting to 15 N.m (11 lb. ft.). Ensure clearance is still greater than 13mm (1/2") for line and clip.

10. Bleed left front brake line.

11. Lower vehicle.

12. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

April 1996

Dear General Motors Customer:

If this condition were to occur in a situation where stopping distances were minimal, a vehicle crash could occur without prior warning.

To prevent the possibility of this condition occurring, your dealer will inspect for proper brake line clearance and reposition those brake lines found to have less than minimal clearance.

Additionally, those brake lines found to have an indentation caused by the contact will be replaced.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date. If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Customer Support Department General Motors of Canada Limited

Object Number: 77600 Size: FS

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.