CAMPAIGN: FUEL LEAKAGE DUE TO IMPROPERLY CRIMPED END RETAIN.
Subject: PRODUCT SAFETY CAMPAIGN 96-C-15 - FUEL LEAKAGE DUE TO IMPROPERLY CRIMPED END RETAINER CLIP ON FUEL RAIL ASSEMBLY
Model and Year: 1996 VEHICLES C/K TRUCKS WITH L29 ENGINE
To: All Chevrolet Dealers
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 repair within sixty (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 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 that is being sent to owners, the owners are being instructed to contact the Chevrolet Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.
DEFECT INVOLVED
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996 Chevrolet C/K Pickup, Crew Cab and Suburban trucks equipped with 7.4L engines (RPO L29 - VIN Code "J"). Some of these vehicles may experience a fuel leak at the fuel rail assembly end plug due to an improperly crimped end retainer clip. If condition were to occur, and an ignition source was present, an engine compartment fire could occur.
To prevent this condition from occurring, dealers are to inspect the fuel rail assembly for Julian date code and replace and fuel rail with a Julian date code of 95318 through 95338. The Julian date code is on the bottom of a white sticker on the fuel rail.
VEHICLES INVOLVED
Involved are certain 1996 Chevrolet C/K Pickup, Crew Cab and Suburban trucks equipped with 7.4L engines (RPO L29 - VIN Code "J") and built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ------------------------------------------------------------------------- 1996 C/K Fort Wayne "Z" TZ111501 TZ118355 1996 C/K Pontiac East "E" TE123567 TE133698 1996 C/K Silao "G" TG102467 TG104526 1996 C/K Suburban Janesville "J" TJ305894 TJ312378 1996 C/K Chassis-Cab Janesville "J" TJ104057 (1 only) 1996 C/K Flint "F" TF0005171 TF0052791
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 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.
PARTS INFORMATION
A preshipment of parts in sufficient quantities to repair all assigned units will be sent to involved dealers at no charge the week of December 18, 1995. In the event a dealer has transferred or traded an involved unit the parts should be forwarded to the appropriate dealer immediately.
Any fuel rail assembly that is required to be replaced must be returned to Delphi Energy at the address shown below. Any new fuel rail assemblies that have been preshipped and are not used should also be returned to Delphi Energy.
Delphi Energy And Engine Management Systems 1000 Lexington Ave. Rochester, NY 14613 ATTN: Floyd Hopkins
Quantity/ Part Number Description Vehicle --------------------------------------------------------------- 1709G076 Fuel Rail Assembly 1 10235071 Intake Manifold Plenum Gasket 2 22514722 O-Ring Seal-Front Fuel Feed Pipe 1 22516256 O-Ring Seal-Fuel Return Pipe 1
OWNER NOTIFICATION
Owners will be notified of this campaign on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).
DEALER CAMPAIGN RESPONSIBILITY
All unsold new vehicles in dealers, possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.
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.
Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
SERVICE PROCEDURE
1. Note settings of all electrical devices and then disconnect negative battery cable.
2. Loosen fuel filler cap.
3. Remove air intake assembly.
4. Remove throttle cable end from throttle body.
5. Remove throttle cable from bracket and move aside.
6. Remove left front wire harness bracket.
7. Remove left rear wire harness bracket.
8. Remove right front wire harness bracket.
9. Remove right rear wire harness bracket.
10. Remove ignition coil from intake manifold.
11. Remove purge and PCV hoses.
12. Remove EGR pipe from adapter on upper plenum.
13. Disconnect all electrical connectors on components attached to upper intake manifold plenum.
14. Remove 8 plenum bolts.
15. Remove upper intake manifold plenum.
16. Confirm Julian date on fuel rail is in the range of 95318 through 95338. If Julian date is outside that range DO NOT change fuel rail and go to step 39. If Julian date in within the above range, proceed to step 17.
17. Install gage J-34730-1A to fuel pressure connection at front of fuel rail.
NOTICE: Wrap a shop towel around fitting while attaching gage to avoid spillage.
18. Place bleed hose into an approved container and open valve to bleed off all pressure.
19. Drain any fuel in gage into an approved container.
20. Remove map sensor hold down bracket.
21. Disconnect fuel injector electrical connector. Remove coil electrical connector and coil.
22. Remove distributor cap.
NOTICE: The screws for the cap are not retained in the cap and may fall out. Use care not to loose screws.
23. Disconnect fuel lines at fittings.
24. Remove 5 fuel rail bolts.
25. Remove fuel rail.
NOTICE: Be certain that all injector 0-rings are retained on the injectors.
26. Remove and discard O-Rings from fuel lines.
27. Lubricate and install new provided 0-rings on fuel lines.
28. Lubricate 0-ring seals for injectors on new fuel rail with clean engine oil.
29. Install new fuel rail using caution not to cut injector 0-ring seals when installing.
30. Install 5 fuel rail bolts and torque front stud to 25 Nm (18 lb. ft.) and other bolts to 10 Nm (8 lb. ft).
31. Connect fuel lines at fittings and torque to 27 Nm (20 lb. ft).
NOTICE: Be certain that new 0-rings are in place on fuel lines and not cut.
32. Connect fuel injector electrical connector.
33. Connect negative battery cable.
34. Install fuel filler cap.
35. Turn ignition switch to "ON" for 2 seconds, to "OFF" for 10 seconds, then to "ON" and check for fuel leaks. Turn ignition to "OFF" after inspection.
36. Install distributor cap and torque screws to 20 lb. in.
NOTICE: The screws for the cap are not retained in the cap. If the cap or rotor are damaged in any way the entire distributor assembly must be replaced.
37. Disconnect negative battery cable.
38. Install MAP sensor hold down bracket and torque to 25 Nm (18 lb. ft).
39. Remove plenum gaskets and clean sealing surfaces with scraper as needed.
NOTICE: Use care when cleaning not to damage sealing surfaces with scrapers or other tools.
40. Install new gaskets onto lower intake manifold.
41. Install upper intake manifold plenum.
42. Install upper plenum bolts and torque to 22 Nm (15 lb. ft.) in sequence shown in 1996 C/K Service Manual, Book 1, Page 6A5-12, Figure 13.
43. Connect all electrical connectors to components attached to upper plenum.
44. Install ignition coil to intake manifold.
45. Install right rear wire harness bracket.
46. Install right front wire harness bracket.
47. Install left rear wire harness bracket.
48. Install left front wire harness bracket.
49. Install EGR pipe to adapter.
50. Install purge and PCV hoses.
51. Install throttle cable to bracket.
52. Install throttle cable end to throttle body.
53. Install AIR intake assembly and torque clamps to 15 Nm (12 lb. ft.).
54. Connect negative battery cable. Start and run engine one minute to verify correct engine operation (no malfunction indicator lamp illumination).
55. Reset all electrical devices as noted in step 1.
56. Install Campaign Identification Label.
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 the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a 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. When installing the new Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.
Apply "Campaign Identification Label" only on a clean, dry surface.
CLAIM INFORMATION
Submit a Product Campaign Claim with the information indicated below:
NOTICE: DO NOT SUBMIT CLAIMS UNTIL AFTER DECEMBER 22, 1995. * FAILED PARTS LABOR LABOR NET REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS AMT ---------------------------------------------------------------- INSPECT - NO FUEL - -- ** MA-96 V9855 1.2 $4.84 RAIL REPLACED INSPECT AND REPLACE- -- ** MA-96 V9856 2.0 $54.59 FUEL RAIL
*For campaign administrative allowance, add 0.1 hours to the "Labor Hours".
**The "Parts Allowance" represents the 40% allowance of the estimated value of parts required needed to complete the repair. The fuel rail assembly used to complete this campaign is not available from GMSPO, therefore the part count and failed part number is to be blank. The 40% allowance, as shown in the above matrix and the customary towing allowance, if appropriate, is to be entered in the Net Amount column.
Refer to the General Motors Corporation Claims Processing Manual for details on product campaign claim submission.
Dear Chevrolet Customer:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
REASON FOR THIS RECALL
General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1996 Chevrolet C/K Pickup, Crew Cab and Suburban trucks equipped with 7.4L engines. Some of these vehicles may experience a fuel leak at the fuel rail assembly end plug due to an improperly crimped end retainer clip. If condition were to occur, and an ignition source was present, an engine compartment fire could occur.
WHAT WE WILL DO
To prevent this condition from occurring, your dealer will inspect and replace the fuel rail assembly if necessary. This service will be performed for you at no charge.
WHAT YOU SHOULD DO
Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service correction is approximately two (2) hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.
The enclosed owner reply card identifies your 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 reply card and returning it to us.
Your Chevrolet dealer is best equipped to provide service to ensure that your vehicle is corrected as promptly as possible. If, however, 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 Chevrolet Customer Assistance Center by calling 1-800-222-1020.
After contacting your dealer and the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington D.C. residents use 202-366-0123).
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.
Chevrolet Motor Division GENERAL MOTORS CORPORATION
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.
