INTERMITTENT FUEL DOOR OPER. (DIAG./APPLY CORRECTION PROC.)

SUBJECT: INTERMITTENT FUEL DOOR OPERATION (DIAGNOSE/APPLY CORRECTION PROCEDURES)

MODELS: 1994 CADILLAC CONCOURS AND DEVILLE BUILT PRIOR TO VIN RU207235

CONDITION:

SOME OWNERS MAY COMMENT ON INTERMITTENT OPERATION OF THE FUEL DOOR RELEASE.

CAUSE:

THE INTERMITTENT OPERATION OF THE FUEL DOOR RELEASE MAY BE CAUSED BY ONE OR MORE OF THE FOLLOWING CONDITIONS:

1. SOLENOID INOPERATIVE.

2. THE FUEL DOOR STRIKER HAS A SHARP EDGE AT THE POINT OF CONTACT TO THE PLUNGER WHICH MAY ABRADE THE PLUNGER.

3. THE FUEL DOOR MAY BIND DUE TO PAINT STICKING TO THE HINGE PIN AND HINGE SPRING.

4. THE SOLENOID PLUNGER MAY FAIL TO RETRACT DUE TO EXCESSIVE SIDE LOAD APPLIED BY THE FUEL DOOR BUMPERS.

5. THE SOLENOID PLUNGER MAY FAIL TO RETRACT DUE TO FREEZING IN POSITION.

6. THE BUMPERS MAY BE STICKING TO THE PAINTED SURFACE ON THE FUEL DOOR INNER PANEL.

CORRECTION:

1. WITH THE FUEL DOOR IN THE OPENED POSITION, (KEY ON WITH GEAR SHIFT IN PARK), PRESS THE RELEASE BUTTON AND OBSERVE THE OPERATION OF THE PLUNGER (FIGURE 1). PROCEED TO STEP 2 IF THE PLUNGER FUNCTIONS NORMALLY. IF THE PLUNGER IS INOPERATIVE:

A.) ALLOW THE VEHICLE TO WARM TO ROOM TEMPERATURE. IF PLUNGER IS FROZEN IN POSITION, THIS WILL ENABLE THE PLUNGER TO MOVE. APPLY 3M 0846 SILICONE PASTE OR EQUIVALENT TO PLUNGER. OPERATE SOLENOID TO ENSURE THAT THE PLUNGER DOESN'T BIND.

* B.) IF THE SOLENOID IS STILL INOPERATIVE, REFER TO SECTION 8A-136 OF THE SERVICE MANUAL FOR DIAGNOSIS OF THE POWER AND GROUND FOR THE SOLENOID.

* NOTE: THIS STEP IS NOT NECESSARY IF SOLENOID IS FUNCTIONING PROPERLY.

2. WITH A FILE, ROUND OFF THE SHARP EDGE OF THE FUEL DOOR STRIKER WHERE IT COMES IN CONTACT WITH THE PLUNGER (FIGURE 1). COAT THE EXPOSED METAL EDGE WITH ZINC-RICH PRIMER AND APPLY TOUCH UP PAINT.

3. WORK THE FUEL DOOR BACK AND FORTH ON THE HINGES TO BREAK THE PAINT BIND ON THE PIN AND SPRING. USING A SCREWDRIVER, OPEN THE HINGE SLIGHTLY (APPROXIMATELY 1/32") AS SHOWN IN FIGURE 2. LUBRICATE THE HINGE AND SPRING WITH 3M 08940 SPRAY LUBE OR EQUIVALENT.

4. TO RELIEVE SIDE LOAD ON THE PLUNGER FROM THE BUMPERS, TRIM 1MM FROM THE TIP OF THE BUMPERS WITH A RAZOR BLADE AS SHOWN IN FIGURE 2. TO KEEP THE BUMPERS FROM STICKING TO THE FUEL DOOR INNER PANEL, LUBRICATE THEM WITH 3M 0846 SILICONE PASTE OR EQUIVALENT.

NOTE: THE SOLID TIP STOP BUMPER ON EARLY VEHICLES HAS SINCE BEEN REPLACED WITH A HOLLOW TIPPED BUMPER, P/N 3547884. THIS NEW BUMPER IS 1MM SHORTER THAN THE ORIGINAL BUMPER AND WILL NOT REQUIRE TRIMMING.

5. TO RELIEVE THE BINDING CONDITION, RESET THE FUEL DOOR FLUSH TO THE QUARTER AT THE REAR OF THE OPENING. THE PLUNGER CAN BE ADJUSTED IN OR OUT +/- 2MM BY LOOSENING THE LATCH ASSEMBLY RETAINING NUT (FIGURE 1). TORQUE THE NUT TO 3.0 N.M (26.5 LBS. IN.).

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION NUMBER: R4060 (SOLENOID DIAGNOSIS AND REPLACEMENT, ONLY IF REQUIRED.) USE PUBLISHED LABOR OPERATION TIME

LABOR OPERATION NUMBER: T3424 (CORRECTION PROCEDURES - STEPS 1-5) LABOR TIME: 0.2

FIGURES: 2

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.

COPYRIGHT 1994 GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.