Customer Satisfaction - Fuel Pump Wiring Replacement (Middle East Only)

THIS CAMPAIGN BULLETIN HAS BEEN REVISED TO EXCLUDE THE REPLACEMENT OF THE HEADLAMP RELAY WHICH IS NOW COVERED IN SAFETY CAMPAIGN 01055 RELEASED AUGUST 2001. ALL COPIES OF BULLETIN 01023 SHOULD BE DESTROYED.

General Motors has decided that certain 2000-2001 Chevrolet Lumina and Caprice model vehicles may exhibit one or more of two conditions. They have been identified as damage to the connector at the interface between the pump wiring within the modular fuel sender assembly and the "pass through" connector at the modular fuel sender assembly cover. This may result in loss of electrical power to the fuel pump, causing a walk home failure, when the fuel pump system fails to operate.

For vehicles identified, dealers are to replace the following:

Involved are certain 2000-2001 Chevrolet Lumina and Caprice model vehicles built during the period of January 2000 through November 2000 and within the following VIN breakpoints:

In addition, any vehicles which have had a fuel pump relay or MRA unit replaced during the period of January 2000 through November 2000 will also be involved in this rework, and have been included in the list of affected vehicles.

Important: Dealers should confirm vehicle eligibility through DCS Screen 445 prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the recall bulletin. The customer name and address data furnished will enable dealers to follow up with customers involved in this recall. Any dealer not receiving a computer listing with the recall bulletin has no involved vehicles currently assigned.

An initial supply of parts required to complete this recall will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin the week of March 26, 2001. Pre-shipped parts will be charged to dealer's open parts account.

Additional parts, if required, are to be obtained from Holden Service Parts Operations. Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

For reference, each kit contains one each of the following:

Note: For standard removal and replacement procedures and safety precautions, refer to the current service procedures in the 1999 Model Year Lumina Service Manual, Volume 3, Section 8A. Only specific tasks for this rework are provided in the following details.

1. Remove fuel pump relay (found in engine bay fuse box) and replace with new level relays.
2. Drain fuel tank as required. Remove the fuel tank (1999 Lumina Service Manual Volume 3, Page 8A-4, Section 2.1).
3. Disconnect and remove the fuel pump wiring patch harness. The fuel pump wiring patch harness is connected between the vehicle body harness and the modular fuel sender assembly.
4. Remove the modular fuel pump and sender assembly. Note: Before removing the modular fuel pump and sender assembly, the electrical connector from the modular fuel pump and sender assembly must be disconnected to ensure it is not damaged by the sender removal tool (1999 Lumina Service Manual, Volume 3, Page 8A-8, Section 2.2).
5. Disconnect and remove the fuel pump harness and fuel gauge sender assembly. (1999 Lumina Service Manual, reference paragraph 2.2, Page 8A-8, Volume 3). Retain the removed harness and sender assembly for warranty validation.

Figure 1

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

=

Submit a Product Recall Claim with the information indicated below.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

Dealers should notify customers using the attached suggested dealer letter.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.