CAMPAIGN:FUEL RETURN HOSE FITTING LEAK OR CRIMP

SUBJECT: PRODUCT SAFETY CAMPAIGN 90C26 FUEL RETURN LINE FITTING CRIMP

MODELS: 1990 M-VAN WITH 4.3L OR 2.5L ENGINE 1990 B6P042 SCHOOL BUS EQUIPPED WITH 366 V-8 GAS ENGINE (LSO) AND 60 GALLON FUEL TANK (NH9)

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 adequately repair within 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 appointments with owners and to repair their vehicles as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owner is being instructed to contact the nearest GMC Zone Office if the dealer does not remedy the condi- tion within five days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time they are instructed how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a relates to motor vehicle safety exists in certain 1990 Chevrolet Astro Vans. These vehicles may have fuel return hoses which may break at either crimped coupling. If this coupling was to separate and an ignition source was present, an engine compartment fire could occur.

To prevent this condition from occurring, a properly crimped fuel return hose will be installed on all involved vehicles.

VEHICLES INVOLVED

Involved are certain 1990 Chevrolet Astro Vans built within the following VIN breakpoints:

Model Year Model Plant From Through ----------- ------ ---------- --------- ---------- 1990 M-Van Baltimore LB107644 LB133720

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer 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 names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged 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 Chevrolet Motor 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. Dealers are to inspect and correct all affected vehicles in new and used vehicle stock prior to their sale.

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 ensure 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 contracted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin.

To prevent this condition from occurring, a properly crimped fuel return hose will be installed on all involved vehicles.

If no owner's name and address were available to GMC Truck Division at the time of campaign initiation the dealer will determine the owner's name and address from the dealership sales records. Please provide this information directly on the second copy of the listing next to the applicable VIN so that records may be updated and the appropriate notification mailed to the owner.This second copy should then submitted to the address listed below in the previously supplied yellow campaign envelopes.

GMC Truck Division General Motors Corporation 101 Union Street Plymouth, Michigan 48170

SERVICE PROCEDURE

1990 M-VAN (See Figure 1)

1. Disconnect negative ground cable from battery.

2. Remove engine cover and disconnect front fuel return line [11 from injector fuel return pipe.

3. Raise vehicle up on hoist.

4. Disconnect front fuel return line [1] from rear fuel return pipe at the left hand frame. Drain excess fuel into an available container.

5. Remove fuel lines clip [7] at bottom of filter [4].

6. Remove fuel filter clamp mounting screw [6] and slide front fuel return line [1] out of clamp [5] and discard return line.

7. Install new front fuel return line [1] in clamp [5] and loosely install clamp mounting screw [6].

8. Reconnect front fuel return line [1] to rear fuel return line and to injector fuel return line. Torque connections to 20-34 N-m (15-25 lb.ft).

9. Reinstall fuel lines clip [7].

10. Tighten filter clamp screw [6] to 9-13 N.m (80-115 lb.in).

11. Lower vehicle.

12. Reconnect battery negative ground cable. Operate engine and check fuel line connections for leakage.

13. Reinstall engine cover.

14. Install "Campaign Identification Label"

PARTS INFORMATION

Parts are to be obtained from General Motors Services Parts Operation (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 instruc- tion code but order under and advice code (2).

Part No. Description Quantity ----------------- -------------- ---------- 15522189 Pipe Assembly 1 Front Fuel Return

Dear Chevrolet Owner:

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

General Motors has determined that a defect which relates to motor vehicle safety exists in certain 1990 Chevrolet Astro Vans. These vehicles may have fuel return hoses which may break at either crimped coupling. If this coupling was to separate and an ignition source was present, an engine compartment fire could occur.

To prevent this condition from occurring, a properly crimped fuel return hose will be installed on all involved vehicles. This service will be completed for you at no charge.

Instructions for performing this service have been sent to your GMC dealer. Parts are available. Please contact your dealer to arrange a service date. The labor time necessary to perform this correction will be approximately 15 minutes. Please ask your dealer how much additional time will be needed to schedule and process your vehicle.

Your Chevrolet dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date and they do not service this condition on that date or within five days, we recommend you contact your nearest Chevrolet Customer Assistance Center by calling 1-800-222-1020.

After contacting your dealer and the Zone Office, 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 Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call 800-424-9393 (Washington, D.C. residents use 366-0123).

The enclosed postage paid owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction to your vehicle in the shortest possible time. If you have sold or traded your vehicle, please furnish us complete name and address of the person you sold or traded your vehicle to and return the card 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.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

Repair Failed Parts Labor Labor * Other Performed PC Part # Allow CC-FC OP HRS Hours ----------- -- -------- ----- ----- ----- ----- ------- Install New 1 15522189 ** SK-00 V6200 0.6 0.1 Front Fuel Return Hose

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outfined in this product campaign bulletin will require a "Campaign Identification Label". Each label provides a space to include campaign number and five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or 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.

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.