CAMPAIGN: FUEL LEAKAGE DUE TO IMPROPERLY CRIMPED END RETAIN.
SUBJECT: FUEL LEAKAGE DUE TO IMPROPERLY CRIMPED END RETAINER CLIP ON FUEL RAIL ASSEMBLY
MODELS: 1996 C/K TRUCKS WITH 7.4L ENGINE (RPO L29, VIN CODE "J")
The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within 60 days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.
If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge, or to a refund of the purchase price less a reasonable allowance for depreciation.
To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule appointments with owners and to repair their vehicles as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owner is being instructed to contact the GMC Truck Division Consumer Relations Office if the dealer does not remedy the condition within five days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed how to contact the National Highway Traffic Safety Administration.
DEFECT INVOLVED
General Motors has decided that a defect, which relates to motor vehicle safety, exists in CERTAIN 1996 C/K trucks equipped with 7.4L engines (RPO L29 - VIN Code "J"). Some of these vehicles may experience a fuel leak at the fuel rail assembly end plug due to an improperly crimped end retainer clip. If this condition were to occur, and an ignition source was present, an engine compartment fire could occur.
To prevent this condition from occurring, dealers are to inspect the fuel rail assembly for Julian date code and replace any fuel rail assembly with Julian date code of 95318 through 95338.
Note: All vehicles already delivered should be towed into the dealership for campaign service and the owner should be provided courtesy transportation. This should be accomplished at no inconvenience to the owner. Additionally, before the unit is returned to the owner it is to be washed and the fuel tank refilled. This should be called to the owner's attention upon completion of the campaign service as a gesture of appreciation from the dealership for their cooperation.
VEHICLES INVOLVED
Involved are CERTAIN 1996 C/K trucks equipped with 7.4L engines (RPO L29 - VIN Code "J") built within the following VIN breakpoints:
Plant Year Model Code From Through -------------------------------------------------------------- 1996 C/K Z Z504135 TZ506451 1996 C/K E E507349 TE510223 1996 C/K G G500738 TG501249 1996 C/K J J702156 TJ704475 1996 C/K F TF000517 TF005279
The specific vehicles involved in this campaign have been identified by Vehicle Identification Number (VIN) Computer Listings. These listings are furnished to all involved dealers with the campaign. Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or SERVICENET prior to beginning campaign repairs.
PARTS INFORMATION
A preshipment of parts in sufficient quantities to repair all assigned units will be sent to involved dealers at no charge the week of December 18, 1995. In the event a dealer has transferred or traded an involved unit, the parts should be forwarded to the appropriate dealer immediately.
Any fuel rail assembly that is required to be replaced MUST be returned to:
Delphi Energy and Engine Management Systems 1000 Lexington Ave. Rochester, NY 14613 Attn: Floyd Hopkins
Any new fuel rail assemblies that have been preshipped and are not used should also be returned to the Delphi address listed above.
Part Number Description Quantity ----------- ----------- -------- 17096076 Fuel Rail Assembly 1 10235071 Intake Manifold Plenum Gaskets 2 22514722 0-Ring Seal, Fuel Feed Front Pipe 1 22516256 0-Ring Seal, Fuel Return Pipe 1
DEALER CAMPAIGN RESPONSIBILITY
All unsold vehicles in dealers' 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 service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.
All vehicles already delivered should be towed into the dealership for campaign service and the owner should be provided courtesy transportation. This should be accomplished at no inconvenience to the owner. Additionally, before the vehicle is returned to the owner it is to be washed and the fuel tank refilled. This should be called to the owner's attention upon completion of the campaign service as a gesture of appreciation from the dealership for their cooperation.
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 the 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 enters your 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.
If the name and address of the owner of an involved vehicle was unavailable to GMC Truck Division at the time of campaign initiation, the dealer must determine the owner's name and address from the dealership sales records. Please provide this information directly on the second copy of the listing next to the applicable VIN so that our records may be updated and the appropriate notification mailed to the owner. This second copy should then be submitted to the address listed below in the previously supplied yellow campaign envelopes.
GMC Truck Division General Motors Corporation 101 Union Street Plymouth, Michigan 48170
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by GMC Truck Division (see copy of owner letter included with this bulletin). A listing of owner names and addresses has been furnished to the involved dealers to enable dealers to follow up with owners involved in this campaign. This listing 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 this campaign.
SERVICE PROCEDURE
1. Note settings of all electrical devices and then disconnect negative battery cable.
2. Loosen fuel filler cap.
3. Remove air intake assembly.
4. Remove throttle cable end from throttle body.
5. Remove throttle cable from bracket and move aside.
6. Remove left front wire harness bracket.
7. Remove left rear wire harness bracket.
8. Remove right front wire bracket.
9. Remove right rear wire harness bracket.
10. Remove ignition coil from intake manifold.
11. Remove purge and PCV hoses.
12. Remove EGR pipe from adapter on upper plenum.
13. Disconnect all electrical connectors on components attached to upper intake manifold plenum.
14. Remove (8) plenum bolts.
15. Remove upper intake manifold plenum.
16. Confirm Julian date on fuel rail is in the range of 95318 through 95338. If Julian date is outside that range do not change fuel rail and go to Step #39. If Julian date is within the above range, proceed to Step 17.
17. Install gage J-34730-1A to fuel pressure connection at front of fuel rail. (Notice: Wrap a shop towel around fitting while attaching gage to avoid spillage.)
18. Place bleed hose into an approved container and open valve to bleed off all pressure.
19. Drain any fuel in gage into an approved container.
20. Remove MAP sensor hold down bracket.
21. Disconnect fuel injector electrical connector. Remove coil electrical connector and coil.
22. Remove distributor cap. (Notice: The screws for the cap are not retained in the cap and may fall out. Use care not to lose screws.)
23. Disconnect fuel lines at fittings.
24. Remove (5) fuel rail bolts.
25. Remove fuel rail. (Notice: Be certain that all injector 0-rings are retained on the injectors.)
26. Remove and discard 0-rings from fuel lines.
27. Lubricate and install new provided 0-rings on fuel lines.
28. Lubricate 0-ring seals for injectors on new fuel rail with clean engine oil.
29. Install new fuel rail using caution not to cut injector 0-ring seals when installing.
30. Install (5) fuel rail bolts and torque front stud to 25 Nm (18 lb. ft) and other bolts to 10 Nm (8 lb. ft).
31. Connect fuel lines at fittings and torque to 27 Nm (20 lb. ft) (Notice: Be certain that new 0-rings are in place on fuel lines and not cut.)
32. Connect fuel injector electrical connector.
33. Connect negative battery cable.
34. Install fuel filler cap.
35. Turn ignition switch to "ON" for 2 seconds, to "OFF" for 10 seconds, then to "ON" and check for fuel leaks. Turn ignition to "OFF" after inspection.
36. Install distributor cap and torque screws to 20 in. lb. (Notice: The screws for the cap are not retained in the cap. If the cap or rotor are damaged in any way, the entire distributor assembly must be replaced.)
37. Disconnect negative battery cable.
38. Install MAP sensor hold down bracket and torque to 25 Nm (18 lb. ft).
39. Remove plenum gaskets and clean sealing surfaces with scraper as needed. (Notice: Use care when cleaning not to damage sealing surfaces with scrapers or other tools.)
40. Install new gaskets onto lower intake manifold.
41. Install upper intake manifold plenum.
42. Install upper plenum bolts and torque to 22 Nm (15 lb. ft) in sequence shown in 1996 C/K Service Manual, Book 1, Page 6A5-12, Figure 13.
43. Connect all electrical connectors to components attached to upper plenum.
44. Install ignition coil to intake manifold.
45. Install right rear wire harness bracket.
46. Install right front wire harness bracket.
47. Install left rear wire harness bracket.
48. Install left front wire harness bracket.
49. Install EGR pipe to adapter.
50. Install purge and PCV hoses.
51. Install throttle cable to bracket.
52. Install throttle cable end to throttle body.
53. Install air intake assembly and torque clamps to 15 Nm (12 lb. ft).
54. Connect negative battery cable. Start and run engine one minute to verify correct engine operation (no malfunction indicator lamp illumination).
55. Reset all electrical devices as noted in Step 1.
56. Install Campaign Identification Label.
WARRANTY INFORMATION
Dealers should submit an accurately filled out Warranty Repair Order on each vehicle completed under this campaign.
Labor Labor *Other **Net Description CC FC Op Hrs Hrs Amount ----------- -------------------------------------- Inspect Only - No Fuel Rail Replaced MA 96 V9855 1.2 0.1 $4.84 Inspect - Replace Fuel Rail MA 96 V9856 2.0 0.1 $54.59 Wash Vehicle MA 96 T2470 --- --- t Fuel Top-Off MA 96 T2471 --- --- tt
* Campaign Administrative Allowance
**The amount identified in the "Net Amount" column represents 40% of dealer net for parts that are furnished in this campaign.
t The amount to be entered in the "Net Amount" column should represent the cost for a customer car wash up to $6.00.
tt The amount of fuel used to fill the customer's vehicle should be entered at the same price per gallon as the current PDI allowance and is not to exceed the total gallons allowed at PDI.
NOTE: The published policy for courtesy transportation is to be followed. Customary towing allowances should be added to Net Item total, no authorization is required.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle corrected 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 and five (5) digit dealer code of the dealer performing the campaign service. This information must be inserted with a typewriter or ball point pen. This label is to be used in conjunction with the clear protective plastic cover provided with the Campaign Identification Labels.
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.
Additional Campaign Identification Labels and covers are available in sheets of 49 by calling VISPAC, Incorporated at 1-800-269-5100 (Monday through Friday 8:00 AM to 4:30 PM EST).
ADMINISTRATIVE PROCEDURE
Procedures covering this campaign are outlined in Section IV of your dealership's "WINS Claims Processing Manual".
Dear GMC Truck Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
General Motors has decided that a defect, which relates to motor vehicle safety, exists in CERTAIN 1996 C/K trucks equipped with 7.4L engines. Some of these vehicles may experience a fuel leak at the fuel rail assembly end plug due to an improperly crimped end retainer clip. If this condition were to occur, and an ignition source was present, an engine compartment fire could occur.
To correct this condition, your GMC Truck dealer will inspect and replace the fuel rail assembly if necessary. This service will be performed for you at no charge.
Instructions for performing this service have been sent to your GMC Truck dealer. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will be approximately 2 hours and parts are available. Please ask your dealer how much additional time will be needed to process your vehicle.
Your GMC Truck dealer is best equipped to provide service to ensure 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 service this condition on that date or within five days, we recommend you contact GMC Truck Consumer Relations by telephone. Consumer Relations will assist you and your dealer in getting your vehicle corrected. The telephone number of the Consumer Relations office is listed in your Warranty and Owner Assistance Information Manual.
After contacting your GMC Truck dealer and GMC Truck Consumer Relations, if you are still not satisfied that we have done our best to remedy this condition without charge 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 800-424-9393 (Washington, D.C. residents use 202-366-0123).
The enclosed postage paid owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please furnish us complete name and address of the person you sold or traded your vehicle to and return the card 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 product.
GMC TRUCK DIVISION General Motors Corporation
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.
