CAMPAIGN: FUEL FEED & RETURN HOSE/PIPE ASSEMBLIES
1987 Pontiac Sunbird and Buick Skyhawk Equipped With 2.0L (RP0 LT2 or LT3, VIN Code K or M) Engine
TO: ALL GENERAL MOTORS DEALERS
DEFECT INVOLVED:
General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in some 1987 Pontiac Sunbirds and Buick Skyhawks equipped with 2.0L engine. The fuel feed and/or return hose/pipe assemblies could crack or separate allowing fuel to leak into the underhood area. This condition could ultimately result in an underhood fire without prior warning. Such a fire could, in time, spread to the passenger compartment and cause injury to any remaining occupants.
To prevent the possibility of this condition occurring, both the fuel feed and return hose/pipe assemblies will be replaced.
VEHICLES INVOLVED:
Involved are certain 1987, Pontiac Sunbird and Buick Skyhawk models with a 2.0L engine and produced within the following VIN breakpoints:
MODEL/YEAR FROM THROUGH ---------- ---- -------
1987 Skyhawk SOP EOP
1987 Sunbird SOP EOP
All affected vehicles have been identified by the VIN listing provided to involved Dealers with this bulletin. Any Dealer not receiving a listing was not shipped any of the affected vehicles.
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 new or 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.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the Dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.
CAMPAIGN PROCEDURE:
Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION:
All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION:
Parts required should be ordered through regular channels as follows:
Quantity/ Usage Part Number Description Vehicle - ----- ----------- ----------- ----------
W/2.OL LT2 10106034 Fuel Feed Asm. 1 W/2.OL LT2 10106035 Fuel Return Asm. 1 W/2.OL LT3 10106037 Fuel Feed Asm. 1 W/2.OL LT3 10106038 Fuel Return Asm. 1
Fuel feed and return hose/pipe, assemblies each come with one (1) "0"-Ring for attachment at engine end. "0"-Rings for chassis end attachment must be ordered separately.
W/2.OL LT2 or LT3 22514722 "0"-Ring - Fuel Feed 1 W/2.OL LT2 or LT3 22516256 "0"-Ring - Fuel Return 1
PARTS AND LABOUR CLAIM INFORMATION:
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card, RAPID terminal or DCS transmission in accordance with the following:
Repair Code Description Time Allowance ----------- ----------- --------------
2A Install Fuel Hose Assemblies W/LT2 Engine 1.1
3A Install Fuel Hose Assemblies .7 W/LT3 Engine
Time allowance includes 0.1 hour for Dealer administrative detail associated with this campaign. Parts credit will be based on Dealer net plus 30% to cover parts handling.
SERVICE PROCEDURE:
TBI ENGINE (RPO LT2, VIN CODE K) - REFERENCE FIGURE 1
1. CAUTION: To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before servicing fuel system components.
Have a dry chemical (Class B) fire extinguisher near work area.
To relieve the fuel system pressure do the following:
- Remove "Fuel Pump" fuse from fuse block in passenger compartment.
- Crank engine - engine will start and run until fuel supply remaining in fuel lines has been consumed. Engage starter for 3.0 seconds to assure relief of any remaining pressure.
Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.
2. Disconnect negative battery cable.
3. Use a backup wrench when loosening the screw coupling fittings at the fuel line ends.
4. Disconnect heater inlet hose at bottom side of manifold for easier fuel line removal.
5. Install new 0-rings on the chassis fuel line ends (See Figure 1) Return Line 0-ring (P/N 22516256) and Feed Line 0-ring (P/N 22514722). The engine end 0-rings are supplied with the new fuel lines.
6. Install new engine fuel lines (Fuel Feed [P/N 10106034] and Fuel Return [P/N 10106035]). Avoid any routing that causes kinking or twisting of the lines.
7. Reconnect heater inlet hose and add coolant if necessary.
8. Secure all fuel line routing clamps.
9. Tighten all fuel line connections to 30 N.m (22 lb. ft.) torque while using a backup wrench on fittings.
10. Reinstall fuel pump fuse, reconnect battery cable, start engine and check coolant and all previously loosened fuel line connections for possible leaks.
11. Install Campaign Identification Label.
MFI TURBO ENGINE (RPO LT3, VIN CODE M)
1. CAUTION: To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before servicing fuel system components. Have a dry chemical (Class B) fire extinguisher near work area.
To relieve the fuel system pressure do the following:
- Remove "Fuel Pump" fuse from fuse block in passenger compartment.
- Crank engine - engine will start and run until fuel supply remaining in fuel lines has been consumed. Engage starter for 3.0 seconds to assure relief of any remaining pressure.
Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.
2. Disconnect negative battery cable.
3. Use a backup wrench when loosening the screw coupling fittings at fuel line ends.
4. Install 0-rings on the chassis fuel line (See Figure 2) Return Line 0-ring (P/N 22516256) and Feed Line 0-ring (P/N 22514722). Engine end 0- rings are supplied with the new fuel lines.
5. Install new engine fuel lines (Fuel Feed [P/N 101060371 and Fuel Return [P/N 101060381). Avoid any routing that causes kinking or twisting of the lines.
6. Secure all fuel line routing clamps.
7. Tighten all fuel line connections to 30 n.m (22 lb. ft.) torque while using a backup wrench on fittings.
8. Reinstall fuel pump fuse, reconnect battery cable, start engine and check coolant and all previously loosened fuel line connections for possible leaks.
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
Dear General Motors Customer:
This notice has been sent to you in accordance with the Canada Motor Vehicle Safety Act.
General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in some 1987 Pontiac Sunbird and Buick Skyhawk models equipped with 2.OL engine. The fuel feed and/or return hose/pipe assemblies could crack or separate allowing fuel to leak into the underhood area. This condition could ultimately results in an underhood fire without prior warning. Such a fire could, in time, spread to the passenger compartment and cause injury to any remaining occupants.
To prevent the possibility of this condition occurring, both the fuel feed and return hose/pipe assemblies will be replaced. This service will be performed for you at no charge.
Please contact your GM Deater as soon as possible to arrange a service date. Instructions for this service have been sent to your Dealer. The labour time necessary to perform this service is approximately one (1) hour (or thirty (30) minutes if your vehicle is equipped with a turbo charged engine). Please allow some additional time for your Dealer to process your vehicle.
This letter identifies your vehicle. Presentation of this letter to your Dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
Further assistance, if required, may be obtained from the General Motors Zone Office nearest you. Your vehicle Owner's Manual provides the location and phone number of each respective Zone Office.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Technical Services Department General Motors of Canada Limited
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.
