CAMPAIGN: DUAL FUEL TANK RETURN HOSE ROUTING

Subject: PRODUCT SAFETY CAMPAIGN 85Cl5 DUAL FUEL TANK RETURN HOSE PLUMBING INCORRECT

Model and Year: 1985 C60 AND C70 MEDIUM DUTY MODEL CHEVROLET TRUCKS - CONVENTIONALS WITH DUAL 50 GALLON FUEL TANKS (RPO NE6) AND HEAVY DUTY GAS ENGINE EMISSIONS (RPO H5D)

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 owners may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allow- ance 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 which is being sent to owners, the owners are being instructed to contact the nearest Chevrolet Zone Office if their dealer does not remedy the condition within five 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 some 1985 Medium Duty Conventional Models equipped with dual 50 gallon fuel tanks (RPO NE6) and heavy duty gas emissions (RPO H5D) may have the fuel return hose improperly connected between the switching valve and the fuel tank sending units. This incorrect plumbing causes fuel supplied by one tank to be returned to the other tank. If receiving tank is full, this can result in overfilling and fuel leakage from either the fuel tank vent or upper fuel vapor canister.

This overflow of fuel could ignite on the engine components and cause a fire without prior warning. Until this condition is corrected, Chevrolet advises use of only one fuel tank.

To correct this condition it is necessary to reposition one of the fuel return hoses and replace the other return hose with a longer one. Since the possibility exists that fuel may have been pumped into the 2500 cc fuel vapor canister, it will be necessary to replace it.

VEHICLE INVOLVED

Involved are certain 1985 C60 and C70 Medium Duty Model Chevrolet Trucks Conventionals with RPO NE6 and H5D, built within the following vehicle parameters:

PLANT FROM THROUGH -------- -------- -------- Pontiac FV202729 FV211339

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Iden- tification Number, owner name and address data, and are furnished to the 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 regis- tration 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 was not shipped any involved vehicles.

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.

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.

SERVICE PROCEDURE

CAUTION:

To prevent possible accidents when working on fuel systems, provide the appropriate fire fighting and safety equipment in accordance with local fire and safety regulations.

NOTE: The return hoses are the only hoses which may be improperly installed.

1. With ignition key on "OFF" position, disconnect the negative battery cable.

2. Inspect the two fuel return hoses located at and/or near the fuel sending unit on the right hand fuel tank for correct routing. These hoses are labeled "RTN" and "RETURN" in Figure No. 1. If vehicle has proper fuel tank return hose routing, no further action is required. Install campaign completion label. If vehicle has improper fuel tank return hose routing, complete the remaining steps of this procedure to correct the condition.

3. Locate the hose labeled "RETURN" in Figure No. 1. This illustration shows the correct positioning of the new 15 inch length of fuel return hose. Cut the nylon tie wrap around the harness block.

4. Remove the old fuel return hose from the harness block.

5. Insert the new return hose in the block harness.

6. Connect hoses to proper location using existing hose clamps.

7. Do not allow hose to chafe or kink after installation.

8. Using a nylon tie wrap, resecure the harness block.

9. On models equipped with a tilt hood, the 2500 cc evaporative emission canister is located on the right front fender well (see Figure No. 2). On models w/o tilt hood the 2500 cc evaporative emission canister is located in front of the left side fender well. In both cases the 2500 cc emission canister will be the larger of the two canisters on the vehicle.

10. Disconnect all hoses going to it and note the hose locations.

11. Remove old canister and replace with new one.

12. Secure hold down screw and reconnect all hoses to proper location.

13. Reconnect negative battery terminal.

14. Install campaign completion label.

PARTS INFORMATION

Parts are to be obtained from the General Motors Warehousing and Distri- bution Division (GMWDD). To ensure that these parts will be obtained as soon as possible, they should be ordered from GMWDD on a C.I.O. order with no special instruction code, but order on an advise code (2).

All vehicles involved in this campaign will require the following parts:

PART NUMBER DESCRIPTION QUANTITY --------- ------------ -------- 17085896 Canister 1

8877974 Nylon Tie Wrap 1

15" (inches) of 1/4" 15 inches Fuel Hose CM Spec #6198-M (P/N 8885522)

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

Parts Failed Parts Failure Labor Labor *Other Count Part No. Allowance Code Operation Hours Hours

00 V2870 .2 .1

DESCRIPTION: Inspect fuel return hoses for correct routing only. No further action.

Parts Failed **Parts Failure Labor Labor *Other ***Net Count Part No. Allowance Code Operation Hours Hours Amount ----- -------- --------- ----- --------- ----- ----- ------ 3 17085896 00 V2871 .7 .1 2.70

DESCRIPTION: Inspect and correct fuel return hose routing. Replace emission canister.

*Campaign Administrative Allowance.

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

***The $2.70 in the "Net Amount Column" represents the material allowance for 15" of fuel hose used in conjunction with labor operation V2871.

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.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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 five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint pen. -------------------- | CAMPAIGN | | 85Cl5 | | COMPLETED | | | | ZN/DEALER CODE | | 199-999 | | DO NOT | | REMOVE | | | -------------------- 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.

ADMINISTRATIVE PROCEDURE

REFER TO THE CURRENT CHEVROLET SERVICE POLICIES AND PROCEDURES MANUAL AND CLAIMS PROCESSING MANUAL FOR CAMPAIGN HANDLING AND ADMINISTRATIVE PROCEDURES.

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.