CAMPAIGN: FUEL SENDER SEAL DISPLACEMENT, INSPECT/REPAIR. GMC Truck S15 Pickup - 2WD 1991

For 1990-2009 cars

# CAMPAIGN: FUEL SENDER SEAL DISPLACEMENT, INSPECT/REPAIR

#### SUBJECT: FUEL SENDER TO TANK SEAL DISPLACEMENT

#### MODELS: 1991 S/T 4-DOOR SPORT UTILITIES (MORAINE ASSEMBLY ONLY)

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 nearest GMC Zone 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 determined that certain 1991 S/T Sport Utility vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Stan- dard (FMVSS) 301, "Fuel System Integrity". Some vehicles may have been shipped with the fuel tank sender seal out of position. In the event of a roll-over accident, an out of position seal could allow fuel spillage in excess of the amount prescribed by FMVSS 301. If an ignition source was present, fuel leakage resulting from this mispositioned seal could result in a fire.

To correct this condition, dealers will inspect vehicles to determine if the fuel sender/pump seal has become displaced and replace those seals that have become displaced.

#### VEHICLES INVOLVED

Involved are certain 1991 S/T 4-Door Sport Utilities built at Moraine Assembly within the following VIN breakpoints:

Model Year From Through ---------- -------- --------- 1991 M2501228 M2546510

The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are furnished to all involved dealers with the campaign 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. Dealers are to correct all affected vehicles in new and used vehicle stock prior to their sale.

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 ensure 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 correction according to instructions contained in this bulletin.

This bulletin is notice to you that the new motor vehicles involved in this campaign may not comply with the standard identified above. Under Section 108 of the National Traffic and Motor Vehicle Safety Act, 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 Standard. 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 for each such sale.

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

#### NOTICE: IT IS EXPECTED THAT LESS THAN 1% OF THE VEHICLES INVOLVED IN THIS CAMPAIGN WILL EXPERIENCE THE CONDITION DESCRIBED.

#### A INSPECTION

#### CAUTION:

GASOLINE OR GASOLINE VAPORS ARE HIGHLY FLAMMABLE. IF AN IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.

1. Disconnect the negative battery cable. 2. Remove fuel tank filler cap to relieve any fuel vapor pressure. 3. Reinstall fuel tank filler cap and tighten until an audible "click" is heard. 4. Remove fuel vapor canister purge line from canister fitting marked "TANK". 5. Disconnect radiator pressure test cap from Radiator Pressure Test Pump- Kent Moore J 24460-01 or equivalent. 6. Insert threaded and of Radiator Pressure Tester Hose into fuel tank vapor purge line. 7. Pressurize the fuel tank and emissions system with 30 strokes of the Radiator Pressure Tester Hand Pump. The pressure gauge on pump will indicate a low amount of pressure. Note the location of the needle in relationship to the gauge and monitor for one minute. If the emissions system, fuel tank filler cap and fuel tank sender seal ring are correctly installed there should be no loss of pressure.

#### NOTICE: DO NOT, UNDER ANY CIRCUMSTANCE, USE SHOP AIR HOSE IN PLACE OR RADIATOR PRESSURE TESTER HAND PUMP. OVER PRESSURIZING OF THE FUEL TANK OR EMISSIONS SYSTEM COULD LEAD TO SYSTEM LEAKAGE OR DAMAGE. IF AND IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR.

8. After one minute, slowly remove fuel tank cap while listening for pressure being released past the filler cap threads.

- If release of pressure is evident the seal ring has not been displaced. Go to Step 9. Stop at Step 12.

- If no pressure is detected when fuel tank filler cap is removed it will be necessary to remove fuel tank to replace fuel tank sender seal ring. Proceed to Procedure B.

9. Disconnect Radiator Pressure Tester Hand Pump hose from fuel tank purge hose.

10. Reconnect fuel tank purge hose to fuel vapor canister.

11. Reconnect negative battery cable.

12. Install Campaign identification Label.

B. REPLACEMENT OF FUEL SENDER SEAL RING

#### CAUTION:

GASOLINE OR GASOLINE VAPORS ARE HIGHLY FLAMMABLE. IF AN IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.

1. Drain fuel from tank.

#### CAUTION:

NEVER DRAIN OR SMRE GASOLINE IN AN OPEN CONTAINER, DUE M THE POSSIBILITY OF FIRE OR EXPLOSION.

2. Raise vehicle on hoist. 3. Remove fuel tank plastic shield. 4. Support fuel tank and remove brackets. (Figure 1) 5. Disconnect fuel tank filler neck. 6. Disconnect fuel lines at filler neck. 7. Lower tank and disconnect fuel lines and electrical connections at sender. 8. Remove fuel sender and seal ring using tool J 36608 or J 24187 (Figure 2). 9. Replace seal P/N 3893116 and reinstall sender using tool J 36608 or J 24187. 10. Raise tank and reconnect fuel lines and electrical connections at sender. 11. Reconnect fuel lines at filler neck. 12. Reconnect fuel tank filler neck. 13. Reinstall fuel tank brackets and tighten bracket bolts to 45 N-m (33 lb. ft.). 14. Install fuel tank plastic shield. 15. Reinstall fuel. 16. Reinstall fuel tank filler cap. 17. Remove tester from purge line. 18. Reinstall purge line to vapor canister. 19. Reinstall negative battery cable. 20. Install Campaign Identification Label.

#### PARTS INFORMATION

Parts are to be obtained from General Motors Service Parts Operation (GMSPO). To insure 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 on an advise code (2).

Part Number Description Quantity -------- ------------ --------------- *3893116 Seal Ring 1 Seal Ring Per *Pkg. of 10 Truck

#### WARRANTY INFORMATION

Dealers should submit a warranty claim on each vehicle completed under this campaign.

Labor Operation Time Trouble Number Description Allowance Code -------- --------------- ---------- ----- V6780 Pressurize Fuel .2 Hr. 96 System-No Loss Of Pressure

V6781 Pressurize Fuel 1.1 Hr. 96 System Pressure Loss-Remove Fuel Tank and Install Fuel Sender 1 Seal Ring

*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 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 may be inserted with a typewriter or ball point pen.

Each "Campaign identification Label" is to be located on the radiator core support in and 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.

Dear GMC Truck Owner:

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

General Motors has determined that certain 1991 S/T Sport Utility vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard (FMVSS) 301, 'Fuel System integrity". Some vehicles may have been shipped with the fuel tank sender seal out of position. in the event of a rollover accident, an out of position seal could allow fuel spillage in excess of the amount prescribed by FMVSS 301. If an ignition source was present, fuel leakage resulting from this mispositioned seal could result in a fire.

To correct this condition, dealers will inspect vehicles to determine if the fuel sender/pump seal has become displaced and replace those seals that have become displaced. This service will be completed for you at no charge.

Instructions for performing this service have been sent to your GMC dealer. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will vary from 20 minutes to 1-1/2 hours. Please ask your dealer how much additional time will be needed to process your vehicle.

Your GMC 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 con- tact your nearest GMC Truck Zone Office by telephone. The Zone Office will assist you and your dealer in getting your vehicle corrected. The telephone numbers of the Zone Offices are listed in your Warranty and Owner Assistance Information Manual.

After contacting your dealer and the Zone Office, if you are still not satisfied with the action we have taken to remedy this non-compliance, you may submit a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street S.W., Washington, D.C. 20590, or call the toll free Auto Safety Hotline at 1-800-424-9393 (Washington D.C. residents may call 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 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.