CAMPAIGN: ENG. OIL COOLER LINE MISROUTED W/TURBO Y92

MODELS AFFECTED 1989 Grand Prix W/Turbo Option Y92

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 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 an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owners are being instructed to contact the Pontiac Customer Assistance Center if their 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, owners are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in some 1989 Pontiac Turbo Grand Prix models (RPO Y92) built with LG5 3.1L turbocharger engines.

During modification of this vehicle, the turbocharger oil feed pipe was misrouted. The misrouted pipe may contact the positive battery cable connecting stud on the starter motor. This then could cause an electrical ground which may result in an engine compartment fire. To prevent the possibility of this condition occurring, the misrouted pipe will be properly routed, then a newly designed clamp and bracket will be installed to locate the pipe away from the starter.

VEHICLES INVOLVED

Involved are certain 1989 Turbo Grand Prix vehicles produced within the following VIN breakpoints:

Up To Model Year Plant Beginning And Including ----- ---- ----- --------- ------------- W 1989 Fairfax KF289693 KF331524 (Turbo)

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings 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 the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of Owner Letter included with this bulletin).

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.

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.

PARTS INFORMATION

The clamp and bracket assembly required to complete this campaign will be shipped directly to involved dealers to cover the number of vehicles on their lists. The parts will be supplied at no charge to the dealers.

If the turbo oil feed line requires replacement, call 1-800-327-8054 to request shipment. It is estimated that less than 10% of vehicles will require replacement of the turbo oil feed line. The turbo oil feed line removed from the vehicle must be returned to the address below to receive your 30% mark-up.

ASC Inc. 18640 Walnut Southgate, MI 48195 Attention: Bob Borowski/Turbo Campaign Quantity Description Part Number Per Vehicle ----------- ----------- ------------ Clamp & Bracket Assembly NPN 1

Turbo Oil Feed Line 12397797 1

SERVICE PROCEDURE

See Attached Instruction Sheet

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 --------- ---- --------- ----- ----- ------ Install Clamp & Bracket 96 V5520 1.9 0.1 $ .67

Install Clamp, Bracket & Turbo Oil Feed Line 96 V5521 2.4 0.1 9.31

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

* In addition dealerships 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 $.67 identified in the "Net Amount" column represents the 30% parts mark-up for the clamp and bracket.

The $9.31 identified in the "Net Amount" column represents the 30% parts mark-up for the clamp, bracket and turbo oil feed line.

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 proper 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. If Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

TURBO GRAND PRIX TURBOCHARGER OIL AND WATER LINE LOCATING BRACKET INSTALLATION INSTRUCTION SHEET

THE FOLLOWING INFORMATION OUTLINES AND ILLUSTRATES THE PROCEDURE WHICH MUST BE USED TO CORRECTLY INSTALL THE TURBOCHARGER OIL AND WATER LINE LOCATING BRACKET.

Remove or Disconnect (Figs. 1, 2 and 3)

1. Apply protective covers to the front fenders.

2. Intercooler to intake manifold duct asscmbly (1, Fig.1).

3. Negative battery cable.

4. Air cleaner inlet duct to air cleaner assembly (2, Fig. 1).

5. Air cleaner to turbocharger duct at turbocharger (3, Fig. 1).

6. Air cleaner and duct assembly (4, Fig. 1).

7. Turbocharger to intercooler duct (5, Fig. 1).

8. A/C intermediate pressure switch wire connector (1, Fig. 2).

9. Harness wire connector at transmission (2, Fig. 2).

10. Nuts attaching harness ground wires to transmission (7, Fig. 2).

11. Ground wires from transmission (3, Fig. 2).

12. Harness wire connectors at coil pack (4 and 5, Fig.2).

13. Hoist vehicle.

14. Starter solenoid cable (purple wire) from solenoid (6, Fig. 2).

15. Lower vehicle.

Inspect

Oil feed line for any white or gray discoloration or other type of damage. If any of the above conditions are found, replace the oil feed line. If the oil feed line must be replaced, tighten the fittings to the specified torque below (5, Fig. 3).

Tighten

Oil feed line(upper)connection to the turbocharger to 20 Nm (15 lbs. ft.) (5, Fig. 3). Oil feed line (lower) connection to coupling to 11 Nm (8 lbs. ft.) (5, Fig. 3).

Install or Connect

1. Reroute wire harness behind the turbocharger oil and water lines as shown in Fig. 3.

NOTICE: If required to reroute wire harness, disconnect oil feed line at fitting and reconnect.

2. A/C intermediate pressure switch wire connector (1, Fig. 2).

3. Harness wire connector at transmission (2, Fig. 2).

4. Ground wircs to transmission (3, Fig. 2).

5. Nuts to secure harness ground wires to transmission (7, Fig. 2).

Tighten

Nuts to 25 Nm (18 lb. ft.)

6. Harness wire connectors to coil pack (4 and 5, Fig. 2).

7. Hoist vehicle.

8. Starter solenoid cable (purple wirce) to solenoid (6, Fig. 2).

9. Lower vehicle.

10. Remove coil pack attaching bolt (1, Fig. 3).

11. Position turbocharger oil and water locating bracket (2, Fig. 3) to the coil pack and secure with coil pack attaching bolt.

Tighten

Bolt to 25 Nm (18 lb. ft.)

12. Attach oil and water line retaining clips (3 and 4, Fig. 3) to oil and water lines (5 and 6, Fig. 3).

13. Position oil and water line retaining clips to the turbocharger oil and water line locating bracket and secure with bolt (7, Fig. 3).

Tighten

Bolt to 10 Nm (7 lb. ft.)

14. Turbocharger to intercooler duct (5, Fig. 1).

15. Air cleaner and duct assembly (4, Fig. 1).

16. Air cleaner toturbocharger duct at turbo charger (3, Fig. 1).

17. Air cleaner inlet duct to air cleaner assembly (2, Fig. 1).

18. Negative battery cable.

19. Intercooler to intake manifold duct assembly (1, Fig.1).

20. Remove protective covers from the front fenders.

Inspect

1. Start-up of engine.

2. Service engine soon light function.

3. A/C function.

4. For turbochargcr oil line leak at the upper and lower connections. Tighten as required (5, Fig. 3).

5. Allow engine to idle for at least 5 minutes to allow ECM to reset.

R & R Labor Time 1.9 HR ADD- To replace oil line .5 HR

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR THE RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in SOME 1989 Pontiac Turbo Grand Prix models (RPO Y92) build with LG5 3.1L turbocharged engines.

During modification of these vehicles, the turbocharger oil feed pipe was misrouted. The misrouted pipe may contact the positive battery cable connecting stud on the starter motor. This then could cause an electrical ground which may result in an engine compartment fire.

WHAT WE WILL DO

To prevent the possibility of this condition occurring, the misrouted pipe will be properly routed, then a newly designed clamp and bracket will be installed to locate the pipe away from the starter. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Your Pontiac dealer may have been in contact with you to make this correction. If not, please contact them as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle. It is estimated that parts will be available on or about June 26, 1989. The labor time necessary to perform this service correction is approximately 2.0 hours.

Your Pontiac dealer is best equipped to obtain parts and provide service to ensure that 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 remedy this condition on that date, or within five (5) days, we recommend you contact the Pontiac Customer Assistance Center by calling: 1-800-762-2737.

After contacting your dealer and the Pontiac Customer Assistance Center, 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, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 366-0123.

The enclosed Campaign Owner Reply Card identifies your Pontiac vehicle. Presentation of this card to your dealer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Owner Reply Card and returning it 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 products.

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.