CAMPAIGN: PREMATURE PISTON FAILURE
SUBJECT: PREMATURE PISTON FAILURE
MODELS: 1990-1995 CHEVROLET/GMC MEDIUM DUTY C5H, C6H, AND C7H TRUCKS WITH 6.OL (RPO LSO) ENGINES AND AUTOMATIC TRANSMISSIONS
General Motors has determined that CERTAIN 1990-1995 C5H, C6H, and C7H trucks equipped with 6.OL engines (RPO LS0-VIN Code "P") and automatic transmission may experience premature piston failures due to pre-ignition spark plug firing.
To correct this condition, it will be necessary to install a new distributor cap, new distributor rotor, new spark plug wires and new spark plug wire heat shields. On affected 1995 vehicles, only a new distributor rotor is required.
VEHICLES INVOLVED
Involved are CERTAIN 1990-1995 C5H, C6H, and C7H trucks equipped with 6.OL engines and automatic transmissions, and built with the following VIN breakpoints:
Year Make Model From Through
1990 GMC/Chevrolet C5H,C6H,C7H SOP EOP 1991 GMC/Chevrolet C5H,C6H,C7H SOP EOP 1992 GMC/Chevrolet C6H,C7H SOP EOP 1993 GMC/Chevrolet C6H,C7H SOP EOP 1994 GMC/Chevrolet C6H,C7H SOP EOP 1995 GMC C6H,C7H SOP SJ503937 1995 Chevrolet C6H,C7H SOP SJ102582
The specific vehicles involved in this campaign have been identified by Vehicle Identification Number (VIN) Computer Listings. These listings are furnished to all involved dealers with the campaign bulletin. Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System or SERVICENET prior to beginning campaign repairs.
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.
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 vehicle inventory are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin. If the name and address of the owner of an involved vehicle was unavailable to GMC Truck Division at the time of campaign initiation, the dealer must 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 our records may be updated and the appropriate notification mailed to the owner. This second copy should then be 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 OWNER NOTIFICATION ------------------ Owners will be notified of this campaign on their vehicles by GMC Truck Division (see copy of owner letter included with this bulletin). A listing of owner names and addresses has been furnished to the involved dealers to enable dealers to follow up with owners involved in this campaign. This listing 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 this campaign.
SERVICE PROCEDURE
MAKE SURE THE IGNITION SWITCH IS "OFF".
1990-1994 Models Only
1. Remove air cleaner and hoses.
2. Remove spark plug wires and shields from spark plugs and routing clips. It may be easiest to pull the shields out with the wire boots still inserted.
3. Remove distributor cap and spark plug wire assembly, leaving the spark plug wires attached to the cap.
4. Remove the distributor rotor.
5. Install new distributor rotor from kit.
6. Install new distributor cap from kit.
7. Install new spark plug wire harnesses and ignition coil wire from the kit, using the old cap with old wires as a guide. Also refer to Figures 1 through 3.
Note: Special care should be taken when installing the spark plug wire boots to ensure the metal terminal within the boot is fully seated on the spark plug terminal and the boot has not moved on the wire. Although the shields are pre- installed on the boots, make sure the boots are fully into the shields after connection to the spark plugs.
8. Install air cleaner and hoses.
9. Install Campaign Identification Label.
1995 Models Only
1. Remove air cleaner and hoses.
2. Remove distributor cap, leaving spark plug wires attached.
3. Remove distributor rotor.
4. Install new distributor rotor.
5. Re-install distributor cap.
6. Re-install air cleaner and hoses.
7. Install Campaign Identification Label.
PARTS INFORMATION
Parts are to be obtained from General Motors Service Parts operation (GMSPO). To ensure parts are obtained as soon as possible, order them from GMSPO on a C.I.O. order with no special instruction code but order under an advise code two (2).
Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 12528918 Ignition Kit, Engine Pre- 1 1990-1994) Ignition Repair 10477219 Rotor - Distributor 1 (1995 only)
WARRANTY INFORMATION
Dealers should submit a warranty claim on each vehicle completed under this campaign.
Labor Operation *Time Cause Number Description Allowance Code ------------------------------------------------------------------------- V9510 Replace distributor cap and rotor, spark plug .6 HR 96 wires and heat shields V9511 Replace only distributor rotor (1995 model .3 HR 96 year)
* For dealer to receive Administrative Time Allowance associated with this campaign, add 0.1 hour to the Labor Operation Time Allowance.
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 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.
ADMINISTRATIVE PROCEDURE
Procedures covering this campaign are outlined in Section V of your dealership's "GMC Truck Warranty Claims Processing Manual" #P9119 Rev. 2/94.
Dear GM Truck Owner:
General Motors has determined that CERTAIN 1990-1995 Topkick/Kodiaks equipped with 6.OL (LSO) fuel-injected gas engines and automatic transmissions may experience premature piston failures due to pre-ignition spark plug firing.
To correct this condition, it is necessary to install a new distributor cap, new distributor rotor, new spark plug wires and spark plug wire heat shields on most trucks. On 1995 model year trucks only, a new distributor rotor is all that is required. This service will be completed for you at no charge.
Instructions for performing this service have been sent to your GM Medium Duty Dealer, and parts are available. Please contact your GM dealer to arrange a service date as soon as possible. This procedure will take approximately 45 minutes to complete, but you should ask how much additional time your dealer will need to schedule and process your vehicle.
Your GM Medium Duty Dealer is best equipped to 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 no service this condition on that date or within five days, we recommend you contact GM Truck Consumer Relations. Consumer Relations will assist you and your dealer in getting your vehicle corrected. The telephone number of the Consumer Relations office is listed in your Warranty and Owner Assistance Information Manual.
After contacting your GM Truck 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 to the Director, Manufacturers Operations Division (6405J), United States Environmental Protection Agency, 401 M Street, S.W., Washington, D.C. 20460. To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if the recall is not accomplished.
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 the complete name and address of the person you sold or traded your vehicle to and return the card to us.
IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS
The California Air Resources (CARB) requires that vehicle emission recall campaigns be completed prior to California registration renewal. Uncorrected emission recall campaigns will result in the inability to renew your California vehicle registration.
At the time of emission campaign completion, your California dealer will issue a "Campaign Certificate of Completion". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of campaign completion.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our product.
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.
