CAMPAIGN INSUFF. FUEL PUMP PRESS FAULTY F/P DRIVE SOCK. Pontiac Sunbird 1984

For 1990-2009 cars

# CAMPAIGN INSUFF. FUEL PUMP PRESS FAULTY F/P DRIVE SOCK

GENERAL MOTORS HAS DETERMINED THAT SOME 1984 "E", "G" AND "J" SERIES EQUIPPED WITH TURBO-CHARGED ENGINES WERE ASSEMBLED WITH FUEL PUMPS THAT MAY HAVE AN EARLY FAILURE OF THE DRIVE SOCKET. THIS FAILURE RESULTS IN INSUFFICIENT FUEL PUMP PRESSURE TO KEEP THE ENGINE RUNNING. TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO REPLACE THE FUEL PUMP ON VEHICLES INVOLVED. SUSPECT FUEL PUMPS HAVE JULIAN DATE CODES OF 332-3 OR LOWER. (REFER TO FIGURE 1.) VEHICLES INVOLVED ALL 1984 "J" SERIES EQUIPPED WITH 1.8L TURBOCHARGED ENGINES (VIN CODE J) WITH THE FOLLOWING SERIAL NUMBERS: EK400001 THROUGH AND INCLUDING EK425558 ALL 1984 "G" AND "E" SERIES EQUIPPED WITH 3.8L TURBOCHARGED ENGINES (VIN CODE 9) WITH THE FOLLOWING SERIAL NUMBERS: "G" SERIES- EH400001 THROUGH AND INCLUDING EH482861 "E" SERIES- EE400001 THROUGH AND INCLUDING EE421595 PARTS INFORMATION A FUEL PUMP FOR EACH MODEL INVOLVED IS TO BE OBTAINED FROM WDDGM AS LISTED IN THE FOLLOWING CHART: MODEL FUEL PUMP PART NUMBER "G" SERIES 6472230 "E" SERIES 6472231 "J" SERIES 6472143 TO ENSURE THIS PART WILL BE OBTAINED AS SOON AS POSSIBLE, IT SHOULD BE ORDERED FROM WDDGM ON A C.I.O. ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ORDER ON AN ADVISE CODE (2). TECHNICAL PROCEDURE 1. REMOVE FUEL TANK ASSEMBLY. REFER TO PAGE 6C-10 IN THE 1984 CHASSIS SERVICE MANUAL. CAUTION: NEVER DRAIN OR STORE GASOLINE IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF EXPLOSION. 2. REMOVE FUEL PUMP AND TANK GAGE SENDER ASSEMBLY FROM THE TANK. REFER TO PAGE 6C-12 IN THE 1984 CHASSIS SERVICE MANUAL. 3. REPLACE FUEL PUMP AS FOLLOWS: A. NOTE POSITION OF INLET FILTER ON PUMP, THEN GRASP FILTER AND REMOVE BY ROTATING IN ONE DIRECTION WHILE PULLING OFF. REFER TO FIGURE 2. B. DISCONNECT ELECTRICAL TERMINALS FROM PUMP BY GENTLY PRYING UP WITH EDGE OF SCREWDRIVER BLADE. C. IF UNIT HAS A PULSATOR, REMOVE PUMP ASSEMBLY BY PLACING SENDER UPSIDE DOWN ON A BENCH. GRASP PUMP AND PULL DOWNWARDS. PULL PUMP INLET OUT AWAY FROM BRACKET. AVOID BENDING THE PUMP MOUNTING BRACKET AND THE FLOAT ARM WHEN REMOVING OR INSTALLING PUMP. D. IF UNIT HAS A RUBBER HOSE COUPLING, CUT OFF NYLON HOSE CLAMPS, AND COUPLER USING A RAZOR BLADE OR SHARP KNIFE. PROCEED TO STEP 6. E. PULL PUMP AND PULSATOR ASSEMBLY OFF FUEL TUBE. USE ALL THE NEW PARTS INCLUDED WITH FUEL PUMP PACKAGE. F. PLACE RUBBER BUMPER AND PULSATOR (OR COUPLING) ON NEW FUEL PUMP. POSITION PULSATOR FLAT AGAINST BUMPER. G. PLACE NEW RUBBER ISOLATOR ON PUMP INLET AND INSTALL IN SAME MANNER AS REMOVAL; PULLING DOWNWARD ON PUMP WHILE FITTING INLET INTO BRACKET. H. PUSH PUMP UPWARDS UNTIL RUBBER ISOLATOR AND INLET ARE SEATED PROPERLY IN BRACKET. REPOSITION FOAM RUBBER SLEEVE AGAINST RUBBER ISOLATOR, IF NECESSARY. I. IF UNIT HAS RUBBER HOSE COUPLING, LUBRICATE THE FUEL TUBE AND PUMP OUTLET WITH A SMALL AMOUNT OF VASELINE PETROLEUM JELLY, THEN SLIDE THE NEW RUBBER HOSE ONTO THE FUEL PUMP. ASSEMBLE IN SAME MANNER AS STEP C ABOVE. INSTALL NEW HOSE CLAMPS ON COUPLING. J. RECONNECT ELECTRICAL TERMINALS TO THE FUEL PUMP. IF TERMINALS ARE LOOSE ON PUMP BLADES, REMOVE AND SQUEEZE SIDES OF TERMINALS WITH PLIERS TO OBTAIN A TIGHT FIT. K. INSTALL NEW FILTER IN THE SAME POSITION ON THE NEW ELECTRICAL PUMP AS REMOVED ONE WAS ON THE ORIGINAL PUMP. PUSH THE FILTER STRAIGHT ON BY APPLYING PRESSURE TO THE OUTER EDGE OF THE METAL FERRULE BEING CAREFUL NOT TO DAMAGE THE FILTER. WHEN PROPERLY INSTALLED, THE PLASTIC PROTRUSION CAN BE FELT PROJECTING BEYOND THE METAL FERRULE. L. INSPECT PUMP TO ASSURE THAT IT IS PROPERLY SEATED IN BRACKET. 4. USING NEW O-RING, REINSTALL FUEL PUMP AND TANK GAUGE SENDER ASSEMBLY IN TANK. 5. REINSTALL FUEL TANK ASSEMBLY, BEING SURE TO PROPERLY ATTACH THE FUEL FEED, VAPOR AND RETURN HOSES AND ELECTRICAL CONNECTOR. TIGHTEN ALL FUEL LINE CLAMPS TO 1.5 N.M. TORQUE THE TANK STRAP ATTACHING BOLTS TO 34 N.M (25 LB. FT.). 6. INSTALL A CAMPAIGN IDENTIFICATION LABEL.

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.