CAMPAIGN:FUEL TANK LINES LOW TORQUE. Chevrolet Astro

Subject: PRODUCT SAFETY CAMPAIGN 95-C-05 - FUEL TANK LINES LOW TORQUE

Model and Year: 1995 ASTRO VANS

To: All Chevrolet 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 Chevrolet 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 a defect which relates to motor vehicle safety exists in certain 1995 Chevrolet Astro Vans with L35 engines. These vans may have fuel lines attached to the fuel tank with less than the specified torque. During the life of the vehicle, as a result of normal vibrations, these fuel lines may loosen to the point of allowing fuel to leak from the lines when the pump is operating. If an ignition source were present, an under-vehicle fire could occur.

To correct this condition, dealers are to lower the fuel tank and tighten the fuel lines to the proper torque value.

VEHICLES INVOLVED

Involved are certain 1995 Chevrolet Astro Vans with L35 engines built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH ----------------------------------------------------------------- 1995 M/L Vans Baltimore " B" SB119880 SB122466

The following VIN's were corrected at the Baltimore Plant and no further correction is required. If one of these VIN's is at your dealership, only the campaign identification label needs to be applied. The plant did not apply any method of identification to indicate the campaign correction was performed.

1GNDM19W9SB120090 1GNDM19WXSB121376 1GNDM19W3SB120117 1GBEL19W6SB121413 1GBDM19W7SB120148 1GNDM19W7SB121416 1GBDM19W2SB120318 1GBDM19W3SB121592 1GNDM19W2SB120528 1GNDM19W6SB121584 1GNDM19W7SB120623 1GNEL19W4SB121588 1GCDM19W0SB120648 1GBDM19W4SB121613 1GBDM19W9SB120667 1GNDM19W6SB121620 1GNDM19W2SB120738 1GNDM19WXSB121622 1GBEL19W4SB120762 1GNDM19W5SB121804 1GNDM19W9SB120767 1GBDM19W1SB122106 1GBEL19W5SB120821 1GGDM19W6SB122136 1GNEL19W6SB121205 1GBDM19W4SB122259 1GBDM19W6SB121226 1GCDN19W3SB122295 1GNDM19W3SB121333 1GNDM19W2SB122358 1GNDM19W9SB121353 1GNDM19W3SB122384

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 limit the use of this listing to the follow-up necessary 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

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 with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

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

No parts are required to complete this campaign.

SERVICE PROCEDURE

1. Drain fuel from tank using procedure outlined in the 1995 M/L Van Drivability, Emission, And Electrical Diagnosis Manual, section 4E.

2. Raise vehicle.

3. Remove fuel tank plastic shield.

4. Loosen filler neck hose clamp at fuel tank and disconnect fuel tank filler neck from fuel tank.

5. Disconnect fuel feed and return flexible lines.

6. Support fuel tank and remove tank brackets.

7. Lower fuel tank to point where vent hoses and electrical connector can be disconnected from sending unit and disconnect them.

8. Lower fuel tank.

9. Tighten fuel feed and return connectors at sending unit to 27 Nm (20 lb. ft.).

10. Raise fuel tank to point where vent hoses and electrical connector can be connected to sending unit and reconnect them.

11. Install fuel tank brackets and tighten retaining bolts by hand only.

12. Back off locking nut on the outer bolts to prevent the nut from contacting the mounting surface before straps are tight.

13. Tighten inner strap retaining bolts to 35 Nm (26 lb. ft.).

14. Tighten outer strap retaining bolts to 3.4 Nm (30 lb. in.).

15. Tighten lock nuts to 35 Nm (26 lb. Ft.).

16. Reconnect fuel feed and return flexible lines.

17. Connect fuel tank filler neck to fuel tank, and tighten filler neck hose clamp to 2.8 Nm (25 lb. in.).

18. Install fuel tank plastic shield.

19. Lower vehicle.

20. Replenish fuel and check for leaks.

21. Install Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and 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. Additional "Campaign Identification Labels" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

FAILED PARTS LABOR LABOR OTHER REPAIR PERFORMED PC PART NO. ALLOW CC-FC OP HOURS HOURS ------------------------------------------------------------------ Retorque Fuel Lines - - - - - SK-00 V9240 1.2 0.1 At Fuel Sensor Vehicle Previously Repaired - Install - - - - - SK-00 V9241 0.2 0.1 Camp. Ident. Label

* Campaign Administrative Allowance.

Dealers will automatically receive the correct labor allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.

Dear Chevrolet Astro Van Owner:

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

REASON FOR THIS RECALL

WHAT WE WILL DO

To correct this condition, your dealer will lower the fuel tank and tighten the fuel lines to the proper torque value. This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service correction is approximately 1 hour and 15 minutes. Please ask your dealer if you wish to know 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 that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date, and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Chevrolet Customer Assistance Center by calling 1-800-222-1020.

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).

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/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.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

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.