CAMPAIGN: FUEL ROLLOVER VALVE ASSEMBLY
MODELS AFFECTED 1989 Bonneville With 3800 V-6 (RPO LN3, VIN Code C) Engine
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 sixty 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 reasonable equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for deprecation.
To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible.
DEFECT INVOLVED
General Motors has determined that some 1989 Pontiac Bonneville model vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 301, "Fuel System Integrity". The fuel rollover valve assembly may not have been installed on the affected vehicles. In the event of an accident and the vehicle became inverted, a missing fuel rollover valve assembly could allow fuel spillage in excess of the amount prescribed by FMVSS 301. Fuel spillage during and after an accident could result in fire.
To correct this condition, dealers are to replace the fuel sender and pump assembly on vehicles involved.
VEHICLES INVOLVED
Involved are certain 1989 Pontiac Bonneville models produced within the following VIN breakpoints:
Year Plant Beginning Up To and Including ---- ----- --------- -------------------
1989 Willow Run KW200554 KW201921
NOTICE: Only 522 vehicles within this range are involved.
Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer Listings contain the complete Vehicle Identification Number and have been furnished to the involved dealers.
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.
This bulletin is notice to you that the new vehicles included in this campaign may not comply with Federal Motor Vehicle Safety Standard No. 301. Under National Traffic and Motor Vehicle Safety Act, Section 108, it is illegal for a dealer to sell a new motor vehicle which the dealer knows does not comply with an applicable Federal Motor Vehicle Safety regulation. As a consequence, if you sell any of these motor vehicles without first performing the campaign correction, your dealership may be subject to a civil penalty up to $1,000 of each such sale.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.
OWNER NOTIFICATION
It is anticipated that there will be no owner notification required, since dealer invoicing was held on these vehicles.
PARTS INFORMATION
The correct quantity of Kits (P/N 25027120) containing a Fuel Sender and Pump Assembly, (P/N 25094448) and fuel tank 0-ring gasket are being shipped to involved dealers on a "No Charge" basis. Parts will not be billed on dealer parts account.
Dealer should not order parts from GMSPO. If additional parts are necessary, contact your Zone Office.
SERVICE PROCEDURE
1. Handling flammable liquids.
CAUTION:
Before attempting service of any type on the fuel tank, always:
a. Place "no smoking" signs near work area.
b. Be sure to have C02 Dry Chemical (Class B) fire extinguisher handy.
c. Wear safety glasses.
d. Siphon or pump fuel into an explosion proof container.
e. Avoid fuel spillage - gasoline fumes are heavier than air and will collect at floor level.
f. Wear gloves to protect against sharp edges.
2. Fuel pressure relief procedure:
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components. To do this:
a. Disconnect fuel tank harness connector.
b. Crank engine, engine will start and run until fuel supply remaining in fuel lines is consumed. Engage starter for 3.0 seconds to assure relief of any remaining pressure.
c. Turn ignition off. Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.
3. Drain fuel tank using hand operated pump.
CAUTION:
Never drain or store gasoline in open container due to the possibility of fire or explosion.
4. Disconnect the negative battery cable.
5. Disconnect the fuel feed and return lines at the frame rail. Cap the fuel lines to reduce spillage.
6. Loosen the hose clamp and disconnect the vapor hose.
7. Loosen clamps and disconnect the filler neck and vent hose. Remove two exhaust hanger bolts at rear and lower exhaust enough to gain access to fuel tank. Support exhaust with jack stand or cable, etc. Loosen exhaust heat shield and let hang free on pipe. Remove parking brake cable bracket at left fuel tank strap.
8. Support fuel tank and loosen the tank strap bolts and lower the fuel tank.
9. Loosen the fuel sender cam lock ring using special tool J 24187-A.
10. Remove the fuel sender assembly and transfer the lock ring and the two pipe insulators onto the new sender.
11. Install new O-Ring gasket on tank opening.
12. Install new fuel sender and pump assembly (25094448) with a rollover valve into the tank.
o Take caution not to damage or deform pipe or break solder connection at sender cover.
o Take caution in installing the sender to not damage the float assembly.
13. Rotate cam lock ring to the stops using the special tool J 24187-A.
14. Verify that the fuel sender pipes are insulated from top of the fuel tank.
15. Verify fuel tank and underbody noise isolation rubber strips remain in proper position.
16. Install fuel tank to vehicle. Tighten strap bolts to 34 N.m (23 lb. ft.).
17. Reconnect the filler neck and torque clamps to 2.5 N.m (20 lb. in.).
o Assure hose is fully seated and is not kinked or twisted.
o Position clamps for servicing.
18. Reinstall parking brake cable bracket, exhaust shield, and exhaust pipe.
19. Reconnect the fuel tank harness connector.
20. Reconnect fuel lines and torque nuts to 27 N.m (22 lb. ft.). Tighten clamp to 1.6 N.m (12 lb. in.).
21. Verify that fuel line nuts and/or hose clamp do not contact the underbody.
22. Reinstall fuel in tank.
DO NOT RUN FUEL PUMP WHEN TANK IS DRY.
23. Connect the negative battery cable.
24. Start the engine and let it idle.
25. Raise the vehicle and check for fuel leaks at the tank and fuel line connections.
26. Lower the vehicle and verify fuel gage function.
27. Install campaign identification label.
CAMPAIGN IDENTIFICATION LABEL
Each vehicle modified 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, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7901-709).
CLAIM INFORMATION
A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.
DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:
Other* Failure Labor Labor Labor Net** Operation Code Operation Hours Hours Amount --------- -------- --------- ----- ----- ------
Replace Fuel Sender and Pump Assembly 96 V4900 1.1 .1 $47.34
* Dealers will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.
** The $47.34 identified in the 'Net Amount' column represents 30% of the current price of furnished parts. This allowance should be listed as a net items figure in the sublet column of the warranty claim.
FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.
Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.
RECORDING COMPLETION
Repairs submitted for vehicles not involved in the campaign will not be paid.
Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS."
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.
