CAMPAIGN: FUEL TANK MAY FATIQUE OR CRACK (LEAK)

Models: 1989 Chevrolet Cavalier, Corsica and Beretta, Pontiac Sunbird and Tempest Equipped with 2.0L or 2.8L Engine (VIN Codes 1, K, M, or W)

TO: ALL GENERAL MOTORS DEALERS

DEFECT INVOLVED:

General Motors of Canada has determined that a defect which relates to motor vehicle safety may exist in certain 1989 Chevrolet Cavalier, Corsica and Beretta, Pontiac Sunbird and Tempest Model vehicles equipped with 2.0L or 2.8L engines. Some of the involved vehicles may have been built with the potential for a fuel tank leak. Small creases on the underside of the tank may fatigue and crack during pressure cycling of the tank which occurs during normal operation of the vehicle. Over a period of time, a crack may form at the location of the crease and cause the fuel tank to leak. If this leak is undetected and there is an external source of ignition present, this condition could ultimately result in a fire.

To prevent this condition from occurring, Dealers are to inspect all involved vehicles and replace fuel tanks as required per the instructions in the SERVICE PROCEDURE section of this bulletin.

VEHICLES INVOLVED:

Involved are certain 1989 Chevrolet Cavalier, Corsica and Beretta, Pontiac Sunbird and Tempest Model vehicles equipped with a 2.0L or 2.8L engine and produced within the following VIN breakpoints:

Model Assembly Year Model Plant From Through ---- ----- ----- ---- ------- 1989 Cavalier Lordstown K7139145 K7142007

1989 Cavalier Janesville KJ146275 KJ151216

1989 Corsica/ Wilmington KY158700 KY160835 Beretta

1989 Corsica/ Linden KE160817 KE162942 Beretta

1989 Sunbird Lordstown K7526494 K7528727

1989 Tempest Wilmington KY705231 KY705455

All affected vehicles have been identified by the VIN listing provided to involved Dealers with this bulletin. Any Dealer not receiving a listing was not shipped any of the affected vehicles.

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.

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 be sure 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 contacted by the Dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity ----------- ----------- -------- 22536716 Tank, Fuel-2.8L Engine (VIN Code "W") 1 Only

22527083 Tank, Fuel-2.0L Engine (VIN Codes "1," 1 "K" or "M") Only

3893116 O-Ring, Fuel Tank Sender 1

22524101 Sound Insulator, Fuel Tank 2

561270 Sound Insulator, Fuel Tank 1

NOTICE: It is expected that only 16% (one in six) vehicles inspected will require fuel tank replacement; please order tanks accordingly, based on attached involved vehicle listing.

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card, RAPID terminal or DCS transmission in accordance with the following:

Repair Code Description Time Allowance

1A Inspect Fuel Tank 0.3

2A Inspect and Replace Fuel Tank 1.0

Time allowance includes 0.1 hour for Dealer administrative detail associated with this campaign. Parts credit will be based on Dealer net plus 30% to cover parts handling.

NOTE: If towing charges are incurred please claim as an add credit - repair code 7A.

SERVICE PROCEDURE:

1. Place vehicle on hoist and disconnect negative battery cable.

2. Raise vehicle, observing instructions and cautions listed in applicable 1989 Service Manuals (Section OA) regarding hoisting of vehicle.

3. Using Figures 1 and 2, find precise area on bottom of fuel tank to be inspected. The view in Figure 1 is looking up at the bottom of the fuel tank (bottom of Figure 1 is toward the vehicle front end). Figure 2 is a photographic view looking up at the fuel tank bottom at an angle from the rear. ONLY the area shown inside the dashed box on the photograph is to be inspected. Any waviness of the sheet metal OUTSIDE the dashed box is acceptable.

It is expected that only one of every six fuel tanks inspected will be deformed as shown in Figures 1 and 2. Other areas of the tank surface may have some waviness which does not affect tank life.

If the deformation ("raised area") is found at the exact location shown in the Figures, proceed to Step 4; otherwise proceed to Step 6.

4. If the vehicle has a 2.8L engine (VIN Code W), obtain a Fuel Tank P/N 22536716 to replace the tank on the vehicle. For a 2.0L engine (VIN Codes 1, K, L or M), obtain Fuel Tank P/N 22527083.

Also, obtain a fuel sender O-Ring and sound insulators as listed in the Parts Information section.

5. Replace the fuel tank, observing the instructions and CAUTIONS as listed in the appropriate 1989 Service Manual, Section 6C.

6. Lower vehicle, reconnect negative battery cable and install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

General Motors of Canada has determined that a defect which relates to motor vehicle safety may exist in certain 1989 Chevrolet Cavalier, Corsica and Beretta, Pontiac Sunbird and Tempest Model vehicles equipped with 2.0L or 2.8L engines. Some of the involved vehicles may have been built with the potential for a fuel tank leak. Small creases on the underside of the tank may fatigue and crack during pressure cycling of the tank which occurs during normal operation of the vehicle. Over a period of time, a crack may form at the location of the crease and cause the fuel tank to leak. If this leak is undetected and there is an external source of ignition present, this condition could ultimately result in a fire.

The fuel tank on your vehicle will be inspected, and if necessary, replaced. This service will be performed for you at no charge.

Please contact your GM Dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your Dealer. The labor time necessary to inspect the fuet tank is approximately fifteen (15) minutes. If replacement of the fuel tank is necessary, approximately fifty-five (55) minutes will be required to service your vehicle. Allow the Dealer extra time to transfer your unused fuel to the new fuel tank. Please ask your Dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

If a fuel tank leak does occur, you may see a puddle of gasoline under the vehicle just ahead of the rear tires, and/or you may smell gasoline. If this occurs, contact your Dealer immediately to service the vehicle. A vehicle leaking fuel should not be left in a confined area or near a source of ignition.

This letter identifies your vehicle. Presentation of this letter to your Dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

Further assistance, if required, may be obtained from the General Motors Zone Office nearest you. Your vehicle Owner's Manual provides the location and phone number of each respective Zone Office.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

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.