Product Safety - Fuel Pressure Regulator-Replace

THIS BULLETIN REPLACES 03054A ISSUED FEBRUARY 2004, AND IS BEING REVISED TO INCLUDE 1998-2000 BUICK LESABRE, PONTIAC BONNEVILLE; 1998-99 OLDSMOBILE EIGHTY-EIGHT; AND 2000 BUICK PARK AVENUE, CHEVROLET MONTE CARLO AND IMPALA MODEL YEAR VEHICLES. DUE TO PARTS AVAILABILITY, 03054B IS BEING CONDUCTED IN 2 PHASES. PHASE 1 WILL CONSIST OF 1998-1999 BUICK LESABRE, PONTIAC BONNEVILLE AND OLDSMOBILE EIGHT-EIGHT MODEL YEAR VEHICLES. PHASE 2 WILL CONSIST OF 2000 BUICK PARK AVENUE AND LESABRE, PONTIAC BONNEVILLE, CHEVROLET MONTE CARLO AND IMPALA MODEL YEAR VEHICLES. PLEASE DISCARD SAFETY RECALL BULLETIN NUMBER 03054A.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-2000 Buick Park Avenue, LeSabre, Pontiac Bonneville; 1998-99 Oldsmobile Eighty-Eight; and 2000 Chevrolet Monte Carlo, Impala model vehicles equipped with a 3.8L V6 (RPO L36 - VIN Code K) engine. These vehicles have a much higher than usual rate of fuel pressure regulator diaphragm leaks. A leak can allow fuel to enter the intake manifold through a vacuum line. In low battery conditions, if the engine does not start when cranked, the fuel from the leaking regulator and a mistimed spark can cause a backfire. The backfire can rupture the intake manifold, causing a loud bang. The rupture of the intake manifold can displace a fuel line, pulling an injector out of place, and causing a fuel leak. If there is an ignition source, a fire can result.

Slow engine cranking and difficulty starting the engine could indicate a low battery. Poor driveability or a check engine light could indicate a fuel pressure regulator leak.

Dealers are to inspect the engine fuel rail and , if necessary, replace the fuel pressure regulator.

Involved are certain 1998-2000 Buick Park Avenue, LeSabre, Pontiac Bonneville; 1998-99 Oldsmobile Eighty-Eight; and 2000 Chevrolet Monte Carlo, Impala model vehicles equipped with a 3.8L V6 (RPO L36 - VIN Code K) engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. the use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Parts Pre-Ship Information -- For US and Canada

Important: An initial supply of Fuel Pressure Regulator Kits required to complete this program will be pre-shipped to involved dealers of record. This pre-shipment is scheduled to begin at the launch of the bulletin revision and will be approximately 20% of each dealer's involved vehicles. Pre-shipped parts will be charged to dealer's open parts account.

Additional parts, if required, are to be obtained from General Motors Service Parts Operations (GMSPO). 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.

Important: The engine could have a BOSCH manufactured fuel rail and fuel pressure regulator. This change could have happened when past service was performed on the vehicle. There should be a Manufacturer's label located on the backside of the fuel rail just below the fuel inlet connector. If the engine has a BOSCH manufacturer's label, dealers should claim 0.2 hr under labor operation V1117 -- "Inspect engine fuel rail, no replacement required" , plus the additional 0.1 hr Administrative Allowance, to close out the recall. If the fuel rail has a DELPHI manufacturer's label, perform the repair as stated in this bulletin.

Inspect the engine fuel rail:

All customer requests for reimbursement for previous repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Product Recall Customer Reimbursement Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs to replace the engine fuel pressure regulator, or replace the upper intake manifold and related repairs due to a ruptured manifold that were performed prior to this notification, are to be submitted by August 31, 2005.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repair are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.2, for specific procedures regarding customer reimbursement verification.

Submit a Product Recall Claim with the information indicated below:

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

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

Letters will be sent to know owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty 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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. 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.

If you have paid to have this recall condition corrected prior to this notification, you may be eligible to receive reimbursement.

Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

Your claim will be acted upon within 60 days of receipt.

If your claim is:

Please follow the instructions on the Claim Form provided on the reverse side to file a claim for reimbursement. If you have questions or need assistance, please contact the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center between the hours of 8:00 AM and 11:00 PM, EST, Monday through Friday. They can be reached at:

Please mail this claim form and the required documents to:

General Motors Corporation

P.O. Box 33170

Detroit, MI 48232-5170

All recall reimbursement questions should be directed to the following number: 1-800-204-0261.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 1998-2000 Buick Park Avenue, LeSabre, Pontiac Bonneville; 1998-99 Oldsmobile Eighty-Eight; and 2000 Chevrolet Impala, Monte Carlo model year vehicles equipped with a 3.8L V6 engine. These vehicles have a much higher than usual rate of fuel pressure regulator diaphragm leaks. A leak can allow fuel to enter the intake manifold through a vacuum line. In low battery conditions, if the engine does not start when cranked, the fuel from the leaking regulator and a mistimed spark can cause a backfire. The backfire can rupture the intake manifold, causing a loud bang. The rupture of the intake manifold can displace a fuel line, pulling an injector out of place, and causing a fuel leak. If there is an ignition source, a fire can result.

Slow engine cranking and difficulty starting the engine could indicate a low battery. Poor driveability or a check engine light could indicate a fuel pressure regulator leak. If you experience these conditions, have your dealer check and repair your vehicle.

If your vehicle does not start and you hear a loud bang, there could be a fuel leak. Do not try to start it again. Contact your dealer for assistance.

Your dealer will inspect the engine fuel rail and, if necessary, replace the fuel pressure regulator. This service will be performed for you at no charge .

This service correction will take approximately 30 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your Buick dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the listed number below:

If, after contacting the appropriate customer assistance center, 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 SW, Washington, DC 20590 or call 1-888-327-4236.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for the recall condition.

More information about this program (including answers to frequently asked questions) is available online at the Owner Center at My GMLink. This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com , and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed form to get the most personalized information for your vehicle.

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 Corporation

Enclosure

03054B