CAMPAIGN: FUEL LEVEL SENDER ARM/TANK INTERFERENCE. GMC Truck S15 Pickup - 4WD 1992

For 1990-2009 cars

# CAMPAIGN: FUEL LEVEL SENDER ARM/TANK INTERFERENCE

********************************************************************** DCS MESSAGE REGARDING STOP DELIVERY ON INVOLVED VINS WAS SENT TO YOU AUGUST 22, 1991 ********************************************************************** GENERAL MOTORS HAS DETERMINED THAT CERTAIN 1992 S/T PICKUPS EQUIPPED WITH 20 GALLON FUEL TANKS (RPO NQE) MAY EXPERIENCE FUEL GAUGE INACCURACIES DUE TO THE FUEL METER FLOAT HANGING UP AGAINST THE SIDE WALL OF THE FUEL TANK RESERVOIR. WHEN THIS OCCURS, THE FUEL GAUGE WILL CONTINUE READING APPROXIMATELY 1/2 FULL REGARDLESS OF HOW MUCH FUEL REMAINS IN THE TANK.

THIS CONDITION MAY BE CORRECTED BY REPLACING THE FUEL METER WITH KIT # 25027768.

VEHICLES INVOLVED

DEALER CODES AND VEHICLES INVOLVED ARE LISTED BELOW:

***CHEVROLET VIN INFORMATION ***

ASSEMBLY PLANT STARTING VIN ENDING VIN

PONTIAC WEST N0100014 N0101228

MORAINE N2100052 N2101700

SCHREVEPORT N8100014 N8101560

*** GMC TRUCK VIN LISTING *** SELLING SHIP TO DEALER CODE DEALER CODE VEHICLE IDENTIFICATION (LIST SORTED IN SELLING DEALER CODE ORDER)

48-06052 48-06052 1GTCS19Z0N2500122 48-06053 48-06053 1GTCS14A2N2500186 48-06081 48-06081 1GTCS19Z0N2500069 48-06182 48-06182 1GTDT14Z8N2500037 48-06182 48-06182 1GTCT14Z9N8500170 48-06182 48-06182 1GTCT14Z5N2500170 48-06503 48-06503 1GTCS14Z6N8500050 48-10005 48-10005 1GTCT14Z3N0500129 48-10012 48-10012 1GTCS14Z4N2500017 48-10036 48-10036 1GTDT14Z7N8500057 48-10099 48-10099 1GTCS14Z9N8500382 48-10129 48-10129 1GTCS14Z9N8500088 48-10129 48-10129 1GTCS19ZXN8500139 48-10191 48-10191 1GTCS14Z8N8500101 48-10197 48-10197 1GTCT14ZXN8500078 48-10399 48-10399 1GTCT14Z5N8500134 48-18003 48-18003 1GTDT19Z2N8500363 48-21009 48-21009 1GTCT14Z2N8500141 48-21084 48-21084 1GTCS19Z7N8500079 48-21085 48-21085 1GTCS14Z2N8500126 48-21104 48-21104 1GTCS14Z4N8500029 48-21215 48-21215 1GTDT14Z1N2500087 48-21689 48-21689 1GTCS19ZXN8500044 48-21706 48-21706 1GTCS14A2N2500124 48-26029 48-26029 1GTCS14Z1N0500164 48-26299 48-26299 1GTCS14Z6N8500145 48-26518 48-26518 1GTCT14Z2N8500043 48-30264 48-30264 1GTCS14A4N8500008 48-30365 48-30365 1GTCS19Z8N8500124 48-30593 48-30593 1GTDT14Z8N2500233 48-30617 48-30617 1GTCS19Z5N8500159 48-30617 48-30617 1GTCS14A8N8500206 48-40034 48-40034 1GTCT14Z9N8500024 48-40041 48-40041 1GTCS14A4N8500011 48-40046 48-40046 1GTCT14Z5N8500165 48-42073 48-42073 1GTCS14Z3N8500006 48-42073 48-42073 1GTCS14Z9N8500009 48-42334 48-42334 1GTCS14A0N8500166 48-44113 48-44113 1GTCS14Z6N8500081 48-44113 48-44113 1GTCS14A3N8500095 48-44130 48-44130 1GTCT14Z6N8500076 48-44143 48-44143 1GTCS14A9N8500151 48-50087 48-50087 1GTCS14A0N8500068 48-50197 48-50197 1GTCS19Z0N8500019 48-50223 48-50223 1GTCS14A5N2500263 48-50246 48-50246 1GTCS14Z7N8500056 48-50246 48-50246 1GTCS14Z6N8500131 48-50257 48-50257 1GTCS19Z5N8500016 48-50257 48-50257 1GTCS19Z6N8500140 48-50265 48-50265 1GTCS14A5N8500177 48-50598 48-50598 1GTCS14A4N8500123 48-50875 48-50875 1GTCS14A9N8500117 48-51004 48-51004 1GTCS19Z8N8500284 48-51041 48-51041 1GTCS14A5N8500017 48-51041 48-51041 1GTCS14A5N8500115 48-51041 48-51041 1GTCS14A8N8500156 48-53190 48-53190 1GTCS14A9N8500103 48-53190 48-53190 1GTCS14AXN2500274 48-53208 48-53208 1GTCS14A5N8500230 48-53287 48-53287 1GTCS14Z1N8500148 48-53304 48-53304 1GTCS14Z7N8500025 48-53338 48-53338 1GTCS14Z2N8500191 48-53347 48-53347 1GTCS19Z2N8500054 48-53458 48-53458 1GTCS14A4N8500185 48-53502 48-53502 1GTCS14Z3N8500104 48-53569 48-53569 1GTCS14Z0N8500061 48-53569 48-53569 1GTCS14Z1N8500182

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. DEALERS ARE TO CORRECT ALL AFFECTED VEHICLES IN NEW VEHICLE STOCK PRIOR TO THEIR SALE.

SHOULD VEHICLES BE SOLD INADVERTENTLY FROM YOUR NEW VEHICLE INVENTORY, PRIOR TO REPAIR, OWNERS ARE TO BE CONTACTED BY THE DEALER AND ARRANGEMENTS MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN.

OWNER NOTIFICATION

THERE WILL BE NO OWNER LETTER SENT OUT WITH THIS CAMPAIGN. DUE TO THE STOP SALE ISSUED PRIOR TO VEHICLE SALE, IT IS ANTICIPATED THE VEHICLES SHOULD STILL BE IN YOUR NEW VEHICLE INVENTORY AND SHOULD BE REPAIRED PRIOR TO RETAIL SALE. IF A UNIT HAS BEEN RETAILED, IN ORDER TO MAINTAIN CUSTOMER SATISFACTION, CONTACT THE OWNER IMMEDIATELY AND ARRANGE TO CORRECT THIS CONDITION ON HIS/HER VEHICLE.

SERVICE PROCEDURE

TO REPLACE FUEL METER THE FOLLOWING PROCEDURE MAY BE USED:

1. RELIEVE FUEL PRESSURE FROM SYSTEM FOLLOWING THE PROPER PROCEDURE.

2. REMOVE NEGATIVE BATTERY CABLE.

3. DRAIN FUEL FROM FUEL TANK.

. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.

#### CAUTION:

NEVER DRAIN OR STORE GASOLINE OR DIESEL FUEL IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.

4. USE A HAND OPERATED PUMP DEVICE TO DRAIN AS MUCH FUEL AS POSSIBLE THROUGH THE FILLER NECK. ON SOME FUEL TANK INSTALLATIONS, THE FILLER NECK IS TOO LONG TO GAIN ACCESS TO THE FUEL. IF THE TANK IS NOT FULL, DISCONNECT FILLER NECK NOSE, AT THE FUEL TANK, TO GAIN ACCESS TO THE FUEL.

#### ALTERNATE METHOD:

A. DISCONNECT FUEL FEED PIPE AND ATTACH A HAND OPERATED PUMP DEVICE.

B. ENERGIZE THE FUEL PUMP RELAY.

C. WITH FUEL PUMP RUNNING, OPERATE HAND PUMP TO REMOVE FUEL.

5. RAISE VEHICLE ON HOIST.

6. DISCONNECT PROPELLER SHAFT, MOVE OUT OF THE WAY AND SECURE.

7. REMOVE CLAMPS FROM FILLER NECK HOSE AND VENT LINE. FIGURE 4-45 IN X-9129 S/T TRUCK SERVICE MANUAL, PAGE 4-31.

8. REMOVE FUEL TANK RETAINING STRAPS. FIGURE 4-47 IN X-9129 S/T TRUCK SERVICE MANUAL, PAGE 4-31.

. SUPPORT THE FUEL TANK.

9. REMOVE SENDER UNIT WIRES, HOSES, AND GROUND STRAP.

. LOWER THE FUEL TANK TO GAIN ACCESS.

10. REMOVE FUEL TANK FROM THE VEHICLE.

11. REMOVE SENDER UNIT AND PUMP BY TURNING THE CAM LOCK COUNTER-CLOCKWISE USING TOOL J 36608 OR J 24187. FIGURE 4-34 IN X-9129 S/T TRUCK SERVICE MANUAL, PAGE 4-31.

12. DISCONNECT ELECTRICAL TERMINALS FROM PUMP.

13. REMOVE CLAMPS FROM RUBBER COUPLER.

#### NOTE: MARK POSITION OF STRAINER ON PUMP; REMOVE STRAINER BY ROTATING IN ONE DIRECTION WHILE PULLING OFF AND DISCARD.

14. PULL THE FUEL PUMP UP INTO THE ATTACHING HOSE WHILE PULLING OUTWARD FROM THE BOTTOM SUPPORT.

. DO NOT DAMAGE RUBBER ISOLATOR.

15. INSTALL FUEL PUMP ASSEMBLY INTO THE ATTACHING HOSE.

#### NOTE: THE FUEL PUMP CANNOT BE RUN DRY BECAUSE BEARING DAMAGE CAN RESULT IN AS LITTLE AS 15 SECONDS. ALSO, CARE MUST BE TAKEN NOT TO FOLD OVER OR TWIST THE STRAINER, WHEN INSTALLING THE SENDING UNIT AS THIS WILL RESTRICT FUEL FLOW.

. USE THE NEW STRAINER AND ALIGN TO ORIGINAL POSITION.

16. SEAT RUBBER ISOLATOR AND PUMP SECURELY IN MOUNTING BRACKET.

. TIGHTEN BOTH CLAMPS SECURELY.

17. INSTALL SENDING UNIT AND FUEL PUMP ASSEMBLY INTO THE FUEL TANK.

- USE THE NEW O-RING SEAL.

18. REINSTALL FUEL TANK AS PER SPECIFICATIONS IN FIGURE 4-47 IN X-9129 S/T TRUCK SERVICE MANUAL, PAGE 4-31, AND RECONNECT HOSES AND ELECTRICAL CONNECTORS.

19. CONNECT PROPSHAFT, TORQUE TO 29 N-M (15 LBS. FT.).

20. LOWER VEHICLE.

21. CONNECT NEGATIVE BATTERY CABLE.

22. CHECK OLD FUEL FOR CONTAMINATION BEFORE REFILLING FUEL TANK.

23. START VEHICLE AND INSPECT ALL CONNECTIONS FOR LEAKS.

24. INSTALL "CAMPAIGN IDENTIFICATION LABEL".

PARTS INFORMATION

PARTS ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO). TO ENSURE THAT THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE, THEY SHOULD BE ORDERED FROM GMSPO ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE BUT ORDER UNDER AN ADVISE CODE (2).

QUANTITY PART NUMBER DESCRIPTION PER VEHICLE

25027768 FUEL METER KIT 1

WARRANTY INFORMATION

DEALERS SHOULD SUBMIT AN ACCURATELY FILLED OUT WARRANTY REPAIR ORDER ON EACH VEHICLE COMPLETED UNDER THIS CAMPAIGN.

LABOR OPERATION *TIME TROUBLE NUMBER DESCRIPTION ALLOWANCE CODE

V6960 R & R FUEL (IN TANK) 1.8 HR 96 PUMP

*FOR DEALER TO RECEIVE ADMINISTRATIVE TIME ALLOWANCE ASSOCIATED WITH THIS CAMPAIGN, ADD 0.1 HOUR TO THE LABOR OPERATION TIME ALLOWANCE.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS CAMPAIGN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL". EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER AND THE FIVE (5) DIGIT DEALER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALL POINT PEN.

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.

ADMINISTRATIVE PROCEDURE

PROCEDURES COVERING THIS CAMPAIGN ARE OUTLINED IN SECTION V OF YOUR DEALERSHIP'S "GM TRUCK CLAIMS PROCESSING MANUAL" #P9119. SAVE

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.