CAMPAIGN: UPPER RR SPRING SEAT INSTALL REINFORCEMENT PLATE. Buick Skylark 1992

NOTE: BUICK SENT THIS AS DCS #92-22 CAMPAIGN 92-C-15 PONTIAC PUBLISHED AS BULLETIN 92-C-10

SUBJECT: INCORRECT UPPER REAR SUSPENSION SPRING SEAT INSTALLED -

(BUICK) TO: ALL INVOLVED BUICK DEALERS (VIA OVERNIGHT EXPRESS) INVOLVED ASST. ZONE MANAGERS SERVICE (VIA OVERNIGHT EXPRESS) ASST. ZONE MANAGERS SERVICE - LA ZONE (VIA OVERNIGHT EXPRESS) ATTN: DEALER PRINCIPAL AND SERVICE MANAGER IMPORTANT INFORMATION - DELIVER IMMEDIATELY

(PONTIAC) 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 BUICK 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 DETERMINED THAT CERTAIN 1992 BUICK SKYLARK MODEL VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) 301 --"FUEL SYSTEM INTEGRITY". SOME OF THESE VEHICLES HAVE BEEN BUILT WITH AN INCORRECT SUSPENSION UPPER SPRING SEAT AT THE RIGHT-REAR POSITION. IF THE VEHICLE WAS INVOLVED IN A REAR IMPACT ACCIDENT, THE RIGHT-HAND WHEEL HOUSE FLANGE COULD SEVER THE FUEL TANK FILLER PIPE AND SPILL FUEL. IF AN IGNITION SOURCE WAS PRESENT, FUEL LEAKAGE FROM THIS CONDITION COULD RESULT IN A FIRE.

DEALER ACTION

TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO INSTALL A REINFORCEMENT PLATE TO THE RIGHT REAR COMPARTMENT RAIL.

VEHICLES INVOLVED

BUICK VEHICLES

INVOLVED ARE THE FOLLOWING 1992 BUICK SKYLARK MODELS:

INVOLVED VEHICLES ARE IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER.

ASSIGNED DEALER CODE FLEET OWNER NC655988 34-255 AVIS NC655991 46-026 AVIS (GRAND) NC655997 46-101 ALAMO NC656002 46-101 ALAMO NC656005 33-465 ALAMO NC656016 46-026 AVIS (GRAND) NC656020 45-720 ALAMO NC656021 34-255 AVIS NC656022 41-510 HERTZ

PONTIAC

INVOLVED ARE THE FOLLOWING 1992 PONTIAC GRAND AM MODELS: INVOLVED VEHICLES ARE IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER.

NC288289 NC288291 NC288292 NC288300 NC288301 NC288302 NC288304 NC288307 NC288316 NC288479

OWNER NOTIFICATION

OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY BUICK MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS DCS).

DEALER MATERIAL

IF YOUR DEALERSHIP HAS VEHICLES INVOLVED IN THIS CAMPAIGN, YOU WILL RECEIVE THE FOLLOWING ITEMS:

- LIST OF ALL VEHICLES INVOLVED IN THIS CAMPAIGN ASSIGNED TO YOUR DEALERSHIP.

- ONE (1) RIGHT/REAR UPPER SUSPENSION SPRING SEAT REINFORCEMENT PLATE FOR EACH VEHICLE ON YOUR LISTING AT NO CHARGE.

- ONE (1) CAMPAIGN IDENTIFICATION LABEL FOR EACH VEHICLE.

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 ARE TO BE CONTACTED BY THE DEALER, AND ARRANGEMENTS MADE TO MAKE THE REQUIRED CORRECTION ACCORDING TO INSTRUCTION CONTAINED IN THIS DCS.

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.

PARTS INFORMATION

PARTS REQUIRED TO COMPLETE THIS CAMPAIGN WILL BE SHIPPED DIRECTLY TO ONLY THOSE DEALERS WITH A VEHICLE(S) INVOLVED IN THIS CAMPAIGN ALONG WITH THE CAMPAIGN DCS. PARTS ARE BEING SHIPPED AT NO CHARGE TO THE DEALER.

SERVICE PROCEDURE:

1. POSITION CAR ON FRAME TYPE HOIST. SEE SERVICE MANUAL SECTION 0A. REMOVE RIGHT REAR TIRE AND WHEEL ASSEMBLY.

2. OPEN THE FUEL FILL DOOR AND REMOVE FOUR (4) 7 MM SCREWS FROM THE FUEL FILLER POCKET. WITH FUEL FILLER CAP STILL ON, PARTIALLY PUSH THE FUEL FILLER NECK INWARD. SEE FIGURE 1.

3. RAISE VEHICLE ON HOIST. SEE SERVICE MANUAL SECTION 0A.

4. REMOVE ONE 13 MM BOLT FROM THE CLIP WHICH HOLDS THE FUEL FILLER PIPE TO THE BODY FRAME RAIL. SEE FIGURE 2.

5. REMOVE THREE 7 MM SCREWS FROM THE FUEL FILLER PIPE SHIELD AND REMOVE THE SHIELD. SEE FIGURE 3.

6. REMOVE ONE 10 MM BOLT FROM THE RIGHT REAR BRAKE PIPE SUPPORT BRACKET. SEE FIGURE 4.

7. CAREFULLY PULL THE FUEL FILLER PIPE DOWN (WITH POCKET AND CAP STILL ON) AND POSITION TO THE LEFT SIDE OF THE VEHICLE. IF NECESSARY, USE TAPE TO HOLD THE FILLER PIPE OVER TO THE LEFT SIDE OF THE VEHICLE (AWAY FROM THE RIGHT SIDE).

8. SUPPORT THE RIGHT SIDE OF THE REAR AXLE WITH A JACK STAND.

9. REMOVE THE RIGHT REAR LOWER SHOCK ABSORBER MOUNTING BOLT AND NUT. REMOVE THE SUPPORTING JACK STAND.

IMPORTANT: NOTE THE POSITION OF THE UPPER END OF THE SPRING AND THE UPPER SPRING INSULATOR BEFORE REMOVING. THE SPRING AND UPPER INSULATOR SHOULD BE RE-INSTALLED IN THE SAME POSITION AS BEFORE REMOVAL.

10. USING AND APPROPRIATE PRY BAR, PULL DOWN THE RIGHT SIDE OF THE REAR AXLE. REMOVE THE RIGHT REAR SUSPENSION SPRING AND RUBBER INSULATOR.

11. POSITION THE REINFORCEMENT PLATE TO THE SPRING SEAT, FRAME RAIL, AND BODY FLANGE AS SHOWN IN FIGURE 4.

12. MARK THE NINE (9) WELD LOCATIONS ON THE SPRING SEAT, FRAME RAIL AND THE BODY FLANGE AS SHOWN IN FIGURE 4.

13. REMOVE THE PAINT FROM THE MARKED WELD LOCATIONS.

14. POSITION THE REINFORCEMENT PLATE AS SHOWN IN FIGURE 4. CLAMP IN POSITION AS REQUIRED.

15. COVER THE FUEL FILLER PIPE, FUEL FILTER, AND ANY OTHER EXPOSED COMPONENTS WITH A PROTECTIVE WELDING TARP.

16. USING A MIG WELDER WITH EZ GRIND ER 70S-16 (OR EQUIVALENT) WELD WIRE, WELD THE REINFORCEMENT PLATE TO THE VEHICLE AS FOLLOWS (SEE FIGURE 4):

IMPORTANT: DO NOT ATTACH THE WELDER GROUND LEAD TO THE REAR AXLE. THE WELDER GROUND LEAD MAY BE ATTACHED TO ANY OTHER PART OF THE VEHICLE BODY WHICH WILL PROVIDE A SAFE. EFFECTIVE GROUND FOR WELDING PURPOSES.

A. PLUG WELD THE REINFORCEMENT PLATE TO THE FRAME RAIL AT THE FOUR HOLES IN THE HORIZONTAL SURFACE OF THE REINFORCEMENT PLATE.

B. LAP WELD THE LOWER EDGE OF THE REINFORCEMENT PLATE TABS TO THE SPRING SEAT.

C. PLUG WELD THE REINFORCEMENT PLATE TO THE BODY FLANGE AT THE THREE HOLES IN THE OUTBOARD FLANGE OF THE REINFORCEMENT PLATE. CLAMP AS NECESSARY TO INSURE GOOD WELDS.

D. REMOVE WELD RESIDUE FROM WELDED AREAS USING A WIRE BRUSH OR OTHER SUITABLE TOOL.

17. APPLY AN APPROPRIATE PRIMER MATERIAL TO ALL WELD AREAS AND LET DRY. APPLY RUBBERIZED UNDERCOATING (PENRAY RUBBERIZED UNDERCOAT - #4424, OR EQUIVALENT) TO THE ENTIRE REINFORCEMENT PLATE AND TO ALL PRIMED AREAS.

18. USING AN APPROPRIATE PRY BAR, PULL DOWN THE RIGHT SIDE OF THE REAR AXLE FAR ENOUGH TO POSITION AND INSTALL THE RIGHT REAR SUSPENSION SPRING AND UPPER INSULATOR ASSEMBLY.

IMPORTANT: THE SPRING AND UPPER INSULATOR SHOULD BE RE-INSTALLED IN THE SAME POSITION AS BEFORE REMOVAL.

19. SUPPORT THE RIGHT SIDE OF THE REAR AXLE WITH A JACK STAND AND LOOSE ASSEMBLE THE LOWER SHOCK ABSORBER BOLT AND NUT. REMOVE THE JACK STAND. TIGHTEN LOWER SHOCK ABSORBER BOLT AND NUT TO 47 N.M (35 LB. FT.).

20. PLACE THE FUEL FILLER PIPE UP INTO POSITION IN THE RIGHT REAR WHEEL HOUSE.

21. LOWER VEHICLE FAR ENOUGH TO ALLOW PROPER POSITIONING OF THE FUEL FILLER NECK AND POCKET ASSEMBLY TO THE OPENING IN THE QUARTER PANEL. INSTALL FOUR (4) 7 MM SCREWS AND TIGHTEN UNTIL FULLY DRIVEN, SEATED, AND NOT STRIPPED.

22. RAISE VEHICLE.

23. RE-INSTALL ONE (1) 10 MM BOLT TO THE RIGHT REAR BRAKE PIPE SUPPORT BRACKET. TIGHTEN TO 20 N.M (15 LB. FT.)

24. RE-INSTALL THE FUEL FILLER PIPE SHIELD TO THE WHEEL HOUSE USING THREE (3) 7 MM SCREWS. TIGHTEN SCREWS UNTIL FULLY DRIVEN, SEATED, AND NOT STRIPPED. SEE FIGURE 1.

SERVICE PROCEDURE CONT.

25. RE-INSTALL ONE (1) 13 MM BOLT TO THE FUEL FILLER PIPE CLIP AND THE BODY FRAME RAIL. TIGHTEN TO 16 N.M (12 LB.FT.). SEE FIGURE 2.

26. LOWER VEHICLE AS REQUIRED TO RE-INSTALL TIRE AND WHEEL ASSEMBLY. TIGHTEN WHEEL NUTS TO 140 N.M (100 LB.FT.).

27. LOWER VEHICLE.

28. INSTALL CAMPAIGN IDENTIFICATION LABEL.

CAMPAIGN IDENTIFICATION LABEL

EACH VEHICLE CORRECTED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS PRODUCT BULLETIN WILL REQUIRE A "CAMPAIGN IDENTIFICATION LABEL." EACH LABEL PROVIDES A SPACE TO INCLUDE 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.

APPLY "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE.

WARRANTY INFORMATION:

SUBLET PARTS FAILED PART FAILURE LABOR LABOR OTHER DLR. OPER. COUNT PART NO. ALLOW. CODE OP.NO. HR. HRS. MTL.TWG

O INSTALL REINFORCEMENT PLATE TO RIGHT REAR UNDERBODY -- NPN -- 96 V7650 2.5 0.1* **

* CAMPAIGN ADMINISTRATION ALLOWANCE

** USE IF WORK SUBLETED AND FOR COSTS RELATED TO MATERIALS USED IN THE REPAIR. ALSO INCLUDE 30% FOR PARTS ALLOWANCE OF REINFORCEMENT PLATE COST, WHICH IS $11.30.

BUICK BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A DO-IT-YOURSELFER." THEY ARE WRITTEN TO INFORM THESE 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 HAS THAT CONDITION. SEE YOUR BUICK DEALER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THAT INFORMATION.

L. W. HAYWARD RESIDENT SERVICE ENGINEER

DEAR 1992 BUICK SKYLARK OWNER:

THIS NOTICE IS SENT TO YOU IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT.

REASON FOR RECALL

WHAT WE WILL DO

TO PREVENT THE POSSIBILITY OF THIS CONDITION OCCURRING, DEALERS ARE TO INSTALL A REINFORCEMENT PLATE TO THE RIGHT REAR COMPARTMENT RAIL.

THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE.

WHAT YOU SHOULD DO

YOU WILL BE CONTACTED BY YOUR BUICK ZONE TO ARRANGE SERVICE AT YOUR BUICK DEALER. INSTRUCTIONS FOR MAKING THIS CORRECTION HAVE BEEN SENT TO YOUR DEALER AND PARTS ARE CURRENTLY AVAILABLE. THE LABOR TIME NECESSARY TO PERFORM THIS SERVICE IS APPROXIMATELY TWO AND ONE-HALF (2-1/2) HOURS. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH ADDITIONAL TIME WILL BE NEEDED TO SCHEDULE AND PROCESS YOUR VEHICLE.

YOUR BUICK 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 THAT AGREED SERVICE DATE, AND THEY DO NOT REMEDY THIS CONDITION ON THAT DATE OR WITHIN FIVE (5) DAYS, WE RECOMMEND YOU CONTACT THE BUICK CUSTOMER ASSISTANCE CENTER BY CALLING 1-800-521-7300.

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 366-0123).

FLEET ACCOUNTS INVOLVED MAY CONTACT BUICK FLEET SERVICE ON 313-236-1659 REGARDING ANY QUESTIONS CONCERNING COMPENSATION FOR VEHICLES HELD FROM USAGE PER BUICK'S REQUEST.

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.

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.

BUICK MOTOR DIVISION GENERAL MOTORS CORPORATION

ENCLOSURE

92-C-15