CAMPAIGN: NON-COLLISION ENGINE COMPARTMENT FIRES. Pontiac Fiero 1984

MODELS AFFECTED 1984 PONTIAC FIERO MODELS

THIS CAMPAIGN BULLETIN IS BEING REVISED TO DELETE INFORMATION PERTAINING TO ENGINE KITS AND REIMBURSEMENTS AND TO ADD LABOR OPERATIONS FOR REBUILDING OF ENGINES. THIS CAMPAIGN SUPERSEDES ALL OTHER BULLETINS AND DCS MESSAGES WITH REGARD TO 84-C-15.

TO: ALL PONTIAC 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 Pontiac Customer Assistance Center if their 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 on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in some 1984 Pontiac Fieros.

An interaction of the engine compartment environment in 1984 Fieros and maintenance or service related factors results in an unreasonable risk of engine compartment fires. Connecting rod failure and a subsequent engine compartment fire can result from running the engine with low oil levels. Tests have shown that rod failure can occur under certain vehicle maneuvers if the oil level is a half quart below the add mark. A knocking or tapping noise may be heard in the engine prior to this rod failure. If owners hear such a noise, they have been instructed to have their Fiero inspected and repaired immediately.

Improper service procedures may also result in coolant or other flammable materials coming in contact with hot exhaust components. Owners are instructed to have their Fiero serviced again if they notice fluid leaks in the engine compartment.

Additionally, in order to assure that vehicles may not have fluid leaks which result from improper installation of components at the time of original assembly, dealers will also inspect and, if necessary, correct those components.

Engine compartment fires can spread to the passenger compartment and cause injury to occupants. General Motors is urging all owners of 1984 Fieros to return their vehicles to Pontiac dealers for the inspection and repairs specified in this bulletin.

VEHICLES INVOLVED

Involved are certain 1984 Pontiac Fiero model vehicles produced within the following VIN breakpoints:

UP TO YEAR/MODEL PLANT BEGINNING AND INCLUDING ---------- ----- --------- ------------- 1984 Fiero Pontiac EP200001 EP336842

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. These 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 name and address data obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other reason 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.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of owner letter included with this 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.

Whenever a vehicle subject to this campaign is taken into your used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

CAMPAIGN SERVICE PROCEDURE

To prevent severe engine damage and to correct fluid leaks which may lead to fires, Pontiac dealers will do the following at no charge to owners:

1. Diagnose and correct engine connecting rod knock.

2. Check for and correct significant engine oil, transmission fluid and engine coolant leaks.

3. Check for and correct improperly routed hoses and wiring, or combustible material on or near the exhaust system/manifold.

4. Check and correct as required, the thermostatic air cleaner system and install a new air filter element.

5. Change the oil and oil filter. An AC type PF-51 oil filter and 4.0 quarts of oil will be used (and is to be used for all future scheduled maintenance service). This will reduce the possibility of engine damage due to low oil level.

6. Install a newly calibrated engine oil dipstick.

7. Install a "Check Engine Oil At Every Fuel Fill" label on the fuel filler door.

8. Update pages 5-8 and 6-4 of the Owners Manual.

9. Replace original Maintenance Schedule booklet with revised booklet. A copy of the revised booklet will be sent to each involved owner with the owner letter.

10. Provide oil, oil filter and air filter changes at a special reduced rate for six (6) years or 60,000 miles from the date the vehicle was originally placed in service, whichever occurs first (see Post Campaign Scheduled Maintenance Service Section in this bulletin).

For purposes of customer satisfaction and to assure proper operation of the cooling system, the following will also be performed at no charge to owners:

1. Check the operation of the electrical cooling fan system, and correct as required.

2. Install a new radiator cap to prevent overheating.

3. Check for and install as required, "Coolant Fill Procedure" labels.

SERVICE REPAIR PROCEDURES

The 1986 Fiero Service Manual provides updated information with regards to fluid leak detection/correction and other procedures and should be used for the purpose of this campaign service.

CAUTION:

PROPER SERVICE PROCEDURES AND SAFETY PRACTICES, AS DESCRIBED IN THE REFERENCED SERVICE MANUAL, MUST BE FOLLOWED. FAILURE TO FOLLOW PROPER SERVICE PROCEDURES, INCLUDING ALL SAFETY PRECAUTIONS, COULD CREATE CONDITIONS THAT MAY LEAD TO ENGINE COMPARTMENT FIRES, POSSIBLY CAUSING INJURY TO PERSONS SERVICING AND/OR OPERATING THE VEHICLE.

1. If a connecting rod knock is evident, see Engine Repair Procedure section in this bulletin (Page 10) otherwise proceed to Step 2.

2. Check for significant fluid leaks and correct as required. This should include the following:

NOTE: Fluorescent oil and coolant additive can be ordered through Kent-Moore by calling 1-800-345-2233.

A. ENGINE COOLANT LEAK DETECTION/CORRECTION: ---------------------------------------- NOTE: Prior to performing coolant leak detection, refer to service bulletins 86-6(Gasoline)-39 and 84-6(Gasoline)-73.

NOTE: Slight coolant leakage from the head gasket may occur initially when performing a pressurized leak test on a "Cold" new engine which has not been previously started. Normally, this initial leakage will stop once the engine has been operated at normal temperatures for approximately ten (10) minutes.

1. Inspect all coolant and heater hoses for leakage and/or deterioration, correct/replace as required.

2. With engine cold perform a pressurized leak test as described in 1986 Fiero Service Manual Section 6B-14, 15. Correct leaks found. If a coolant leak is evident but cannot be located, a special flourescent coolant additive and a "high intensity" ultraviolet black light may be used to determine leak location.

3. With engine cold, remove radiator cap and add 1 oz. contairer flourescent coolant additive (Kent-Moore P/N J-29545 or equivalent) to coolant system.

4. Install new radiator cap P/N 10036879.

5. Check for correct operation of the engine cooling fan system per 1986 Fiero Service Manual Section 8A-31-1 through 8A-31-15. Correct irregularities.

6. Start engine and allow it to reach normal operating temperature. One on-off cycle of electric coolant fan signifies engine is at normal operation temperature.

7. Inspect for external leaks by using a black light. Correct as necessary.

8. If no external evidence of a leak is found, remove cover from valve lifter area and inspect per Pontiac Dealer Service Management Bulletin 84-SM-34C (refer to Figure 1). With engine warm and pressure applied, coolant should be visible using a black light. If condition is evident, see Cracked Block Information section in this bulletin.

B. ENGINE OIL LEAK DETECTION/CORRECTION: ------------------------------------ 1. If visual inspection of engine does not reveal source of oil leak, use a black light with fluorescent oil additive (one 1-oz. container Kent-Moore P/N J28431-B or equivalent), refer to 1986 Fiero Service Manual, Section 6-5.

2. To correct oil leaks from sheet metal covers, replace necessary covers with latest available service parts (refer to appropriate parts book). Use RTV sealant P/N 1052915 and ensure mating surfaces are thoroughly cleaned and free of any dirt, grease, oil, etc. before applying sealant.

NOTE: Refer to service bulletins 86-6(Gasoline)-49 and 86-6(gasoline)-35 for proper removal procedures of rocker arm cover and push rod cover, respectively.

C. TRANSMISSION FLUID LEAK DETECTION/CORRECTION: -------------------------------------------- Inspect for automatic or manual transmission fluid leaks per 1986 Fiero Service Manual, Section 7A-3. For manual transmission fluid leak detection the "Powder Method", as described in 1986 Fiero Service Manual, Section 7A-3, is recommended.

SERVICE REPAIR PROCEDURES - CONTINUED FROM PAGE 4

3. Check for proper locations of heat shields and condition of fasteners (See Figure 2). Repair or replace as required.

4. Check and correct improperly routed hoses or wiring or combustible materials on or near exhaust system/manifold.

5. Check and correct thermostatic air cleaner system, including duct work, per 1986 Fiero Service Manual, section 6E2-C14. Clean system and install new air cleaner element P/N 25043317 (AC Type A913C With Foam Wrap - NO SUBSTITUTES!). Secure air cleaner with washer faced nuts torqued 18-35 lb.-in. (2-4 Nm); DO NOT OVERTIGHTEN!

6. Check for presence and legibility of "Coolant System Fill Procedure" label. There should be two (2) labels; one located on engine compartment deck lid and one by radiator cap. Replace or clean as required. Install new labels only on a clean dry surface.

NOTE: If an engine kit, short block was installed, or connecting rod knock repair procedure used proceed to Step 8 (as Step 7 would have been previously performed.

7. Change oil and oil filter. Install AC type PF-51 oil filter P/N 25010908 or equivalent. Install 4.0 quarts SF grade 5W-30 engine oil. Replace old dipstick with new recalibrated dipstick P/N 10101497.

8. Install "Check Engine Oil At Each Fuel Fill" Label (NPN). Install on lower inside surface of fuel filler door below existing "Unleaded Fuel Only" label. Apply label only on a clean, dry surface.

9. Apply updates P/N 10077794 & 10077795 to pages 5-8 and 6-4 respectively of owners manual.

10. Ensure that owner has a copy of the revised maintenance schedule booklet. Provide copies to owners as required.

11. 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, the five digit dealer code of the dealer performing the campaign service and the date the vehicle was campaigned. This information may be inserted with a typewriter or a ball point pen. Install the label only on a clean, dry surface of the rear deck lid where it is readily visible (additional campaign labels are available on stationery order as Form 7901-709).

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (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 on an advise code (2).

The following parts, to be ordered from GMSPO, will be required for each involved vehicle:

Quantity/ Description Part Number Vehicle ----------- ----------- -------- SF 5W30 Engine Oil (55 Gal. Drum) 1052766 4.0 Qts.

AC Type PF-51 Oil Filter 25010908 1

AC Type 913C Air Filter W/Foam Wrap NO SUBSTITUTES 25043317 1

Radiator Cap 10036879 1

Dipstick 10101497 1

In addition, the following parts will be required for each involved vehicle and will be shipped to involved dealers with the campaign bulletin:

Quantity/ Description Part Number Vehicle ----------- ----------- --------- "Check Engine Oil At Every Fuel Fill" Label NPN 1

"Engine Coolant System Fill Procedure" Label 10030499 As Required

Revised 1984 Fiero Maintenance Schedule Booklet 10077793 1

Supplement To 1984 Fiero Owners Manual Page 5-8 10077794 1

Supplement To 1984 Fiero Owners Manual Page 6-4 10077795 1

Additional parts necessary to correct engine compartment fluid leaks, cooling system or thermostatic air cleaner system discrepancies, etc., are to be ordered from GMSPO as required from the appropriate service parts catalog.

CRACKED BLOCK PROCEDURE

1. Pressure test for evidence of coolant loss.

2. If pressure test shows no visible evidence of coolant loss, remove cover from valve lifter area and inspect casting above lifter cavity (see Figure 1).

3. With engine warm and pressure applied, coolant should be visible using a "black light."

4. If condition is evident, cylinder block and those associated parts identified in this bulletin must be replaced using applicable replacement procedures referenced in Section 6A of the 1986 Fiero Service Manual. To prevent camshaft lobe and valve lifter scuffing, use Engine Oil Supplement P/N 1052367 (16 oz.).

ENGINE REPAIR PROCEDURE

Repair rod knocks by performing the following procedure:

CAUTION:

PROPER SERVICE PROCEDURES AND SAFETY PRACTICES, AS DESCRIBED IN THE REFERENCED SERVICE MANUAL, MUST BE FOLLOWED. FAILURE TO FOLLOW PROPER SERVICE PROCEDURES, INCLUDING ALL SAFETY PRECAUTIONS, COULD CREATE CONDITIONS THAT MAY LEAD TO ENGINE COIIPARTMENT FIRES, POSSIBLY CAUSING INJURY TO PERSONS SERVICING AND/OR OPERATING THE VEHICLE.

A. Remove oil pan.

B. Remove connecting rod caps.

C. Remove main bearing caps.

D. Measure connecting rod and main bearing clearances and crankshaft connecting rod journal and main bearing journal diameters, per 1986 Fiero Service Manual, Section 6A-10 through 6A-13.

E. If bearing clearances are excessive and none of the bearings have spun, install a new set of rod and main bearings, per 1986 Fiero Service Manual, Section 6A10 through 6A13. If necessary, replace crankshaft. DO NOT INSTALL A REMACHINED CRANK!

If cylinder head removal is necessary, replace all cylinder head bolts with new SAE grade 11.9 bolts. The bolt P/N's are shown below:

SAE Grade Bolt Position 11.9 Bolt P/N ------------- ------------- 1-8 10044566 9 10044568 10 10044570

Head bolt tightening procedure is as follows:

- Clean bolts and head spot faces.

- Oil bolts with engine oil (5W-30).

- Apply sealing compound (P/N 1052080) to threads of bolts #9 and #10.

- Install cylinder head with new head gasket (P/N 10043091) and finger start all head bolts.

- Torque all head bolts to 25 Nm (18.5 lb. ft.) in sequence specified in Figure 3.

- Repeat sequence, bringing torque to 35 Nm (26 lb. ft.) on all bolts except #9. Retorque bolt #9 to 25 Nm (18.5 lb. ft)

- Repeating same sequence, rotate all ten head bolts 90 degrees.

NOTE: Refer to 1986 Fiero Service Manual for proper fastener torque specifications.

F. Install a new oil pan (P/N 10035817, order from GMSPO), per 1986 Fiero Service Manual, Section 6A1-14.

G. Change oil and oil filter. Install AC type PF-51 oil filter P/N 25010908. Install 4.0 quarts SF grade 5W-30 engine oil. Replace old dipstick with new recalibrated dipstick P/N 10101497. Check for proper engine operation and verify that no oil leaks exist following repairs. It is recommended that a black light be used to detect oil leaks per 1986 Fiero Service Manual, Section 6-5, correct as required.

Upon Completion of engine repair, check for oil and coolant leaks by performing steps 2A, 2B, and 2C and continue with balance of service repair procedures. If the above repair procedure is inadequate to restore proper engine operation (engine severely damaged) follow appropriate steps to install a short block assembly as described in Pontiac Dealer Service Management Bulletin 84-SM-34C.

CAUTION:

POST CAMPAIGN SCHEDULED MAINTENANCE SERVICE

Dealers are to provide future scheduled oil, oil filter and air cleaner element changes for owners of 1984 Fieros at a cost to owners of $10.00 for each scheduled service. This service is to be provided for a period of six (6) years or 60,000 miles, whichever occurs first, from the date the vehicle was originally placed in service. In addition, each time this service is performed, the dealer is to inspect for significant fluid leaks in the engine compartment or for the presence of an audible rod knock. If either of these conditions are observed, advise the owner of the additional service required. In these cases, the following shall apply:

A. Coolant leaks diagnosed as outlined in Dealer Service Management Bulletin 84-SM-34C should be covered as set forth in the bulletin.

B. Other fluid leaks and or engine noise related to normal engine wear should be considered owner responsibility.

CAMPAIGN CLAIM INFORMATION

A separate repair order must be kept for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

NOTE: FOR PURPOSES OF REPORTING TO THE FEDERAL GOVERNMENT, IT IS IMPERATIVE THAT THE DEALER USE THE CORRECT LABOR OPERATION NUMBER TO DISTINGUISH THE FAILURE MODE (I.E. CRACKED BLOCK VERSUS ROD KNOCK).

FOR CAMPAIGN INSPECTION AND INITIAL MAINTENANCE

Part Count: Total quantity of parts used (including oil, antifreeze, etc.) Failed Part Number: 25010908 (Oil Filter) Parts Amount: Dealer cost +30% for all parts used. *Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ---- --------- ----- -----

Automatic Transmission 96 V4380 1.4 .1

Manual Transmission 96 V4381 1.8 .1

CONNECTING ROD KNOCK

Crankshaft & Bearing Repair - Including Inspection & Maintenance Part Count: Total quantity of parts used Failed Part Number: Crankshaft Bearings part number - as listed in Parts Catalog Parts Amount: Dealer cost +30% for all parts used in the crankshaft and bearing repair

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Without A/C 96 V4384 10.9 .1

With A/C 96 V4385 11.9 .1

CRACKED BLOCK/CONNECTING ROD KNOCK ---------------------------------- Engine Rebuild - Including Inspection & Maintenance Part Count: Total quantity of parts used Failed Part Number: Block part number - as listed in Parts Catalog Parts Amount: Dealer cost +30% for all parts used to rebuild the engine

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Without A/C 6 V4388 11.3 .1 With A/C 96 V4389 11.8 .1

*In addition, dealership will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit, This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH ABOVE LABOR OPERATIONS.

CORRECTION OF FLUID LEAKS (USE IN CONJUNCTION WITH V4380 OR V4381)

If the campaign inspection and maintenance operation (V4380 or V4381) reveals only fluid leaks, the appropriate "T" labor operation should be selected from the following charts to be used for submission of a warranty claim.

NOTE: FAILURE CODE 95 MUST BE USED WITH ANY OF THE FOLLOWING "T" LABOR OPERATIONS.

AUTOMATIC TRANSAXLE

LABOR LABOR DESCRIPTION HOURS OPERATION ----------- ----- --------- Lines, Oil Cooler/Repair or Repl./Right 1.3 T3177

Lines, Oil Cooler/Repair or Repl./Left 1.3 T3178

Lines, Oil Cooler/Repair or Repl./Both 1.3 T3179

Upper Trans. Oil Cooler Hose Replace .2 T3180

Lower Trans. Oil Cooler Hose Replace .2 T3181

Both Trans. Oil Cooler Hose Replace .3 T3182

Tube and/or Seal Trans. Filler/Replace .4 T3183

T.V. Cable O-Ring Replace .2 T3184

Gov. Cover/Seal - Replace .3 T3185

Pan/Gasket Transmission Replace .6 T3186 Add: To Replace Manual Shaft Seal .1

Cover/Gasket, Valve Body - Replace .7 T3187

Cover/Gasket, Auxillary Valve Body/Repl. .9 T3188

Servo Cover Gasket - Replace .7 T3189

Seal Trans. Axle Shaft, Replace/Right 1.1 T3190

Seal Trans. Axle Shaft, Replace/Left 1.1 T3191

Seal Trans. Converter, Replace 3.5 T3193

Cover and Gaskets Trans. Case/Replace 4.4 T3194 Add: To Replace Case Cover .1

Case, Trans/Replace 5.7 T3195

Generator, Speedo, Signal/Replace .4 T3196

MANUAL TRANSAXLE

Cylinder Clutch Actuator R&R/Replace .4 T3197 Add: To Recondition .2

Line, Clutch Hydr. - Replace 1.1 T3198

Seals, Axle - Replace Right 1.1 T3199

Seals, Axle - Replace Left 1.1 T3200

Seals, Axle - Replace Both 1.5 T3201

Trans or Axle Case Half/R&R/Replace 4.7 T3202

ENGINE

Clamp Rad. Hose - Replace .2 T3203 Add: To Replace Each Addt'l. .1

Coolant Hoses Replace Upper .6 T3204

Coolant Hoses Replace Lower .6 T3205

Replace Both Upper & Lower 1.0 T3206

Coolant Pump Inlet - Replace .4 T3207

Thermos Bypass Hose - Replace .4 T3208

Pump/Gasket Coolant Replace 1.3 T3209

Plate Coolant Pump Cover Replace .3 T3210

Nut/Gasket Fuel Inlet Replace .3 T3211

Pipe Fuel Pump to Throttle Body Unit/Repl. .3 T3212

Sensor Coolant Temp .4 T3213

Seal Trans. Axle Shaft, Replace/Both 1.5 T3192

Pipe Fuel Repair .5 T3214

Coolant Fan Switch/Replace .3 T3215

Engine Coolant Temp Switch/Replace .3 T3216

Thermostat Housing/R & R/Replace .2 T3242

Wiring - Repair .5 T3243

Shield Exhaust/Replace .3 T3244 Each Additional .2

Intake Gasket Replace 2.0 T3217 Add: To Repl. Manifold .2

Rocker Gasket .7 T3172

Gasket Push Rod Side Cover 2.3 T3171

Gasket Cyl. Head 3.1 T3218 With A/C .4

Head, Cyl. Repl. Incl. Trans. of Parts 4.6 T3219 Add: With A/C .4 With Cruise Control .1

Seal, Timing Cover Oil - Replace .7 T3174

Timing Cover/Gasket, Replace 2.0 T3173

Cap Oil Filler Replace .2 T3220

Dipstick Replace .2 T3221

Dipstick Tube Replace .2 T3222

Pan and/or Gasket, Oil Replace 2.3 T3170

Oil Pump Drive and/or Gasket, Replace .5 T3223

Rear Crankshaft Seal Replace 5.9 T3224 W/Auto. Trans. lst Design Only .4

Plug Expansion Replace .3 T3225

Rear Cam Plug & or Cover/Gskt./Replace .3 T3226

Crankcase Ventilation Grommet .2 T3227

Engine Oil Pressure Switch/Replace .3 T3228

HEATER & A/C ------------ Heater Pipe Clamp - Replace .3 T3229

Pipe Heater Inlet - Replace 1.1 T3230

Pipe Heater Outlet - Replace 1.1 T3231

Hose, Htr. Pipe to Eng. Comp. Inlet/Repl. .4 T3232

Hose, Eng. Comp. Inlet to Engine/Repl. .4 T3233

Hose, Htr. Pipe to Engine Outlet/Repl. .4 T3234

Radiator/R & R .8 T3245 With Auto. Trans. .2

ELECTRIC COOLING FAN

Blade/Motor Cooling Fan/Replace .6 T3235

Relay, Cooling Fan Replace .3 T3236

Wiring and/or Connector/Repair .5 T3237

THERMOSTATIC AIR CLEANER

Sensor/Hoses Thermostatic Air Cleaner, .2 T3238 Repair/Repl. Motor, Air Cleaner Vacuum, Replace .3 T3239

IF NO LABOR OPERATION NUMBER IS LISTED FOR THE REPAIR PERFORMED, USE THE CLOSEST APPROPRIATE OPERATION FOUND IN THIS BULLETIN.

POST CAMPAIGN SCHEDULED MAINTENANCE SERVICE CLAIM INFORMATION

A separate repair order must be kept for each vehicle, for each scheduled maintenance service performed. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE MAINTENANCE SERVICE AS FOLLOWS:

Failure Labor Labor Operation Code Operation Hours --------- -------- --------- ----- Change oil & oil filter and perform audio/visual inspection for rod knocks and/or fluid leaks 95 T3175 .3

Change air cleaner element, oil & oil filter and perform audio/visual inspection for rod knocks and/or fluid leaks 95 T3176 .5

NOTE: Refer to Post Campaign Maintenance Service Section in this bulletin for handling of additional claims.

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the proper labor operation as outlined.

Dealers should submit these claims for the full amount of the maintenance cost. The claims processing system will automatically deduct the $10.00 fee paid by the owner.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in this campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

December, 1987

Dear Pontiac Owner:

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

REASON FOR THE RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists ir some 1984 Pontiac Fieros.

An interaction of the engine compartment environment in 1984 Fieros and maintenance or service related factors results in an unreasonable risk of engine compartment fires. Connecting rod failure and a subsequent engine compartment fire can result from running the engine with low oil levels. Tests have shown that rod failure can occur under certain vehicle maneuvers if the oil level is a half quart below the add mark. A knocking or tapping noise may be heard in the engine prior to this rod failure. If you hear such a noise, have your Fiero inspected and repaired immediately.

Improper service procedures may also result in coolant or other flammable materials coming in contact with hot exhaust components. Have your Fiero serviced again if you notice fluid leaks in the engine compartment.

Additionally, in order to assure you that your vehicle may not have fluid leaks which result from improper installation of components at the time of original assembly, we will also inspect and, if necessary, correct those components.

WHAT WE WILL DO

To prevent severe engine damage and to correct fluid leaks which may lead to fires, Pontiac dealers will do the following at no charge to you:

1. Diagnose and correct engine connecting rod knock.

2. Check for and correct significant engine oil, transmission fluid and engine coolant leaks.

3. Check for and correct improperly routed hoses and wiring, or combustible material on or near the exhaust system/manifold.

4. Check and correct as required, the thermostatic air cleaner system and install a new air filter element.

6. Install a newly calibrated engine oil dipstick.

7. Install a "Check Engine Oil At Every Fuel Fill" label.

8. Update pages 5-8 and 6-4 of the Owners Manual.

9. Replace original Maintenance Schedule booklet with revised booklet included with this letter.

10. Provide oil, oil filter and air filter changes at a special reduced rate for six (6) years or 60,000 miles from the date the vehicle was originally placed in service, whichever occurs first.

For purposes of customer satisfaction and to assure proper operation of the cooling system, the following will also be performed at no charge to you:

1. Check the operation of the electrical cooling fan system, and correct as required.

2. Install a new radiator cap to prevent overheating.

3. Check for and install as required, "Coolant Fill Procedure" labels.

WHAT YOU SHOULD DO

Please contact your Pontiac dealer as soon as possible to arrange a service date. Instructions for this service have been sent to your dealer. The labor time necessary to perform this service varies depending on the amount of service your vehicle requires. A minimum of approximately one and one/half (1 1/2) hours is required to perform the necessary service, but please allow some additional time for your dealer to process your vehicle.

Proper vehicle maintenance is necessary to avoid future engine damage, fluid leaks, and possible engine compartment fires. A Maintenance Schedule booklet was included with your owners manual. We are including a revised Maintenance Schedule booklet with this letter. Please familiarize yourself with and follow this revised Maintenance Schedule so that maintenance will be performed at more frequent intervals than displayed in the old booklet.

Engine oil and engine coolant fluid levels should be checked at each fuel fill. Proper oil levels, use of proper engine oil, and oil and oil filter changes at the recommended intervals can prolong engine life (see pages 5-6 through 5-8 of your owners manual as updated by your dealer). Ignoring these maintenance items can cause serious engine damage.

To encourage and promote proper engine maintenance, Pontiac dealers will provide future scheduled oil/oil filter and air filter changes for a total cost of $10.00 for each scheduled service. In addition, each time this service is performed, the dealer will inspect for significant fluid leaks in the engine compartment or for the presence of an audible rod knock. If either of these conditions are observed, you will be advised so that you can arrange for necessary repairs. Based on the nature of the necessary repairs indicated by these later inspections, charges will be determined on an individual basis. This service will be available to 1984 Fiero owners for a period of six (6) years or 60,000 miles from the date the vehicle was originally placed in service, whichever occurs first.

Your Pontiac dealer is best equipped to obtain parts and 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 Customer Assistance Center by calling 800-762-2737.

After calling the Customer Assistance Center, if you are still not satisfied that we have done our best to remedy this condition without charge, within a reasonable time, you may wish to write the Admimistrator, National Highway Traffic Safety Administration, 400 Seventh Street. S.W., Washington, D.C. 2C590, or call 800-424-9393 (Washington, D.C. residents use 366-0123).

The enclosed owner reply card identifies occur Pontiac vehicle. Presentation of the 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.

If you have previously paid for all or part of internal engine damage repairs related to conditions mentioned in this letter, Pontiac will consider claims for reimbursement on an individual basis. If you have a claim, you should present to your dealer, documentation which reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity performing the repair. Documented unreimbursed towing expenses up to $25 will also be considered. Your dealer will assist you in requesting reimbursement from Pontiac. Requests for reimbursements must he received by December 31, 1988.

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.

Object Number: 87600 Size: LF

Object Number: 80827 Size: FS

Object Number: 87599 Size: FS

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.