CAMPAIGN: ENGINE MOUNTED FUEL PIPE FRACTURE
SUBJECT: PRODUCT SAFETY CAMPAIGN 92C31-ENGINE MOUNTED FUEL PIPE FRACTURE
MODEL and YEAR: 1992 CAPRICE WITH 4.3L V-6 ENGINE
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 1992 Chevrolet Caprice model vehicles equipped with 4.3L V-6 engines (RPO LB4). These vehicles have engine mounted fuel feed and return pipes which may fracture due to contact with the engine frame during engine operation. If the pipes fracture, gasoline would be forced out at the fracture location. If an ignition source were present, a fire could result.
To prevent this condition from occurring, dealers are to replace the fuel feed and return pipes using new pipe assemblies.
VEHICLES INVOLVED
Involved are certain 1992 Chevrolet Caprice model vehicles equipped with 4.3L V-6 engines built within the following VIN breakpoints:
PLANT YEAR MODEL PLANT CODE FROM THROUGH ---- ----- ----- ----- ---- ------- 1992 B-Car Arlington "R" NR100003 NR151401
1992 B-Car Willow Run "W" NW100001 NW160964
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
Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 10238119 Fuel Feed Pipe Assembly 1
10238120 Fuel Return Pipe Assembly 1
22514722 Fuel Feed Pipe Seal 1
22516256 Fuel Return Pipe Seal 1
14015367 Air Injector Pipe Gasket 1
SERVICE PROCEDURE
Tool Required: Fuel Line Separator Tool Set J-37088-A
1. Disconnect negative ground cable from battery.
Notice: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing fuel system components.
After relieving pressure a small amount of fuel may be released when servicing fuel pipes or connections. In order to reduce the chance of personal injury, cover fuel pipe fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when disconnect is complete.
2. Loosen fuel filler cap to relieve tank vapor pressure (do not retighten cap until service has been completed). The internal constant bleed feature of the TBI model 220 relieves fuel pump system pressure when the engine is turned "OFF". Therefore, no further action is required.
3. Remove engine oil dipstick.
4. Remove air cleaner assembly.
5. Remove air cleaner assembly bracket. This is a tubular shaped bracket with a center support leg and is located directly behind the air cleaner assembly position. The bracket is attached to the intake manifold and to the top of the EGR (Exhaust Gas Recirculation) valve.
6. Disconnect quick-connect fittings attaching engine fuel feed and return pipes to engine compartment fuel feed and return fuel lines:
A. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. Repeat for other fitting.
B. Using compressed air, blow out dirt from quick-connect fittings.
Notice: Safety glasses must be worn when using compressed air, as dirt particles may cause eye injury.
C. Choose correct tool for size of fitting from J-37088-A tool set.
D. Insert tool into female connector, then push inward to release male connector.
E. Repeat A-D for other fitting.
7. Remove upper fan shroud.
8. Remove serpentine belt.
9. Disconnect EGR, HVAC and MAP vacuum lines.
10. Disconnect ECM sensor connectors and grounds at intake manifold and TBI unit.
11. Remove AIR diverter valve with adapter pipe.
12. Remove IAC valve.
13. Remove lower A/C compressor brace.
14. Remove dipstick tube bolt from cylinder head.
15. Remove upper A/C compressor brace.
16. Remove A/C compressor mounting bolts from passenger side accessory drive bracket.
17. Reposition A/C compressor to a secure location. Do not discharge refrigerant.
18. Remove fuel pipe nut and clip at passenger side accessory drive bracket.
19. Remove engine fuel feed and return pipes from TBI unit.
20. Position/install new fuel feed and fuel return pipes (do not connect).
21. Blow out new fuel lines using shop air.
22. Install new 0-rings and connect new fuel feed and return pipes to TBI unit. Torque fuel pipe attaching nuts to 27 Nm (20 lb. ft.). Use back-up wrench on nuts to prevent them from turning.
23. Install fuel pipe clip and nut at accessory drive bracket. Torque nut to 33 Nm (25 lb. ft.).
24. Position A/C compressor in compressor mounting bracket.
25. Install A/C compressor mounting bolts to compressor and mounting bracket. Torque 2 long bolts to 50 Nm (37 lb. ft.) and short bolt to 80 Nm (60 lb. ft.).
26. Install upper A/C compressor brace onto brace studs using brace nuts. Torque nut holding brace to compressor mounting bracket 33 Nm (25 lb. ft.) and Torque nut holding brace to intake manifold to 25 Nm (18 lb. ft.).
27. Install dipstick tube bolt to cylinder head. Torque bolt to 10 Nm (90 lb. in.).
28. Install lower A/C compressor brace. Torque bolts to 33 Nm (25 lb. ft.).
29. Install IAC valve. Torque to 18 Nm (13 lb. ft.).
30. Install AIR diverter with adapter pipe and new gasket. Torque bolts to 20 Nm (15 lb. ft.).
31. Connect ECM connectors and grounds at intake and TBI unit. Torque nut to 34 Nm (25 lb. ft.).
32. Connect EGR, HVAC and MAP vacuum lines.
33. Install serpentine belt.
34. Install upper fan shroud.
35. Connect fuel feed and return lines to fuel feed and return pipes:
A. Apply a few drops of clean engine oil to male connector tube ends.
Notice: To reduce the risk of personal injury: Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male tube ends of the engine fuel pipes. This will ensure proper reconnection and prevent a possible fuel leak (during normal operation, the 0-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).
B. Push male and female connectors together to cause retaining tabs/fingers to snap into place.
C. Once installed, pull both ends of each connection to make certain connection is secure.
36. Install air cleaner assembly bracket (tubular "U" shaped bracket). Torque nuts to 25 Nm (18 lb. ft.).
37. Install air cleaner assembly.
38. Insert engine oil dipstick assembly.
39. Tighten fuel filler cap.
40. Connect negative ground cable to battery.
41. Start engine and inspect for fuel leaks.
42. Install Campaign Identification Label.
Notice: This campaign is to be performed on all involved vehicles in conjunction with campaign 92C32, "Positive Battery Cable Routing". Some involved vehicles may also require campaign 92C33, "Crankcase Vent Tube Disconnection" to be performed.
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 CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS ---------------- -- -------- ----- ----- ----- --- --- Replace Fuel Feed And Fuel Return 5 10238119 ** SK-00 V7810 1.7 0.1 Pipes
* 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.
Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.
Refer to the Chevrolet Claims Processing Manual for details on Product Campaign Claim Submission.
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.
