CAMPAIGN: DIESEL ENGINE FUEL INJECTION LINE & JAW CLAMP

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: 97064 - DIESEL ENGINE FUEL INJECTION LINE AND JAW CLAMP REPLACEMENT

MODELS: 1995-1997 CHEVROLET AND GMC W5 MODELS EQUIPPED WITH 6HE1-TC DIESEL ENGINES 1995-1996 CHEVROLET AND GMC W6-7 MODELS EQUIPPED WITH 6HE1-TC DIESEL ENGINES

General Motors has decided that certain 1995-1997 Chevrolet and GMC W5, and 1995-1996 W6 and W7 model vehicles all equipped with 6HE1-TC diesel engines may exhibit a condition in which the fuel injection lines may crack from vibration due to the design of the jaw clamps that hold the injection lines in place. This cracking could cause engine power loss or vibration.

To prevent the possibility of this condition occurring, dealers are to replace the injection lines, jaw clamps, and other related hardware with new improved parts.

VEHICLES INVOLVED

Involved are certain 1995-1997 Chevrolet and GMC W5, and 1995-96 W6 and W7 model vehicles equipped with 6HE1-TC diesel engines and built within the following VIN breakpoints:

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1995 Chevrolet W5 Kawaski "3" S3700010 S3701863 1996 Chevrolet W5 Kawaski "3" T3700053 T3700975 1997 Chevrolet W5 Kawaski "3" V3700033 V3701022 1995 Chevrolet W6 Kawaski "3" S3100019 S3100533 1996 Chevrolet W6 Kawaski "3" T3100002 T3100345 1995 Chevrolet W7 Kawaski "3" S3200012 S3201729 1996 Chevrolet W7 Kawaski "3" T3200008 T3200303 1995 Chevrolet W7HV Kawaski "3" S3300009 S3300145 1996 Chevrolet W7HV Kawaski "3" T3300011 T3300056

1995 GMC W5 Kawaski "3" S3700008 S3701878 1996 GMC W5 Kawaski "3" T3700050 T3700987 1997 GMC W5 Kawaski "3" V3700036 V3701031 1995 GMC W6 Kawaski "3" S3100003 S3100534 1996 GMC W6 Kawaski "3" T3100001 T3100380 1995 GMC W7 Kawaski "3" S3200002 S3201734 1996 GMC W7 Kawaski "3" T3200003 T3200249 1995 GMC W7HV Kawaski "3" S3300002 S3300199 1996 GMC W7HV Kawaski "3" T3300008 T3300055

NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or ServiceNet prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer 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.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

Part Quantity/ Number Description Vehicle

97720161 Injection Line Kit 1

CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

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 customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the appropriate divisional customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer 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.

SERVICE PROCEDURE

1. Set the parking brake and block the wheels.

IMPORTANT: Be sure to turn off the engine and remove the key from the ignition switch. This ensures that the engine shutoff lever is set to the OFF position.

2. Disconnect the battery ground cable.

3. Tilt the cab and lock it in place.

4. Remove the retaining nuts securing the existing injection line jaw clamps No. 1 through No. 5 to the intake manifold. Remove and discard the existing jaw clamps and retaining nuts (Figure 1).

CAUTION:

Be extremely careful when loosening and removing fuel lines in the following steps. High pressure may still remain in the lines. Loosen fuel lines slowly to release any stored pressure.

5 . Loosen the retaining nuts on both the injector side and the injection pump side of existing injection lines No. 1 through No. 6 (Figure 1).

6. Remove and discard the existing injection lines No. 1 through No. 6.

7. Remove the retaining nut securing the No. 5 & No. 6 injection line jaw clamp bracket to the intake manifold (Figure 2). Remove and discard the existing injection line jaw clamp bracket.

8. Remove the two retaining bolts securing the secondary fuel filter base to the existing secondary fuel filter bracket (Figure 3). Gently push the fuel filter and filter base away from the filter bracket.

9. Remove the retaining nut securing the large jaw clamp located on the left side of the secondary fuel filter (Figure 4). Remove the large jaw clamp.

10. Remove the three retaining nuts (two upper and one lower) from the existing secondary fuel filter bracket (Figure 5). Remove and discard the secondary fuel filter bracket.

11. Remove and discard the existing studs for injection line jaw clamps No. 1, No. 2, and No. 4 from the intake manifold (Figure 6A, 6B).

12. Install the new studs for injection line jaw clamps No. 1, No. 2, and No. 4, supplied from the kit.

13. Install the new secondary fuel filter bracket supplied from the kit (Figure 7). Tighten the two upper retaining nuts to 40 Nm (30 Ft. Lb.) each. Tighten the lower retaining nut to 18 Nm (13 Ft. Lb.).

14. Gently align the secondary fuel filter base and secondary fuel filter onto the new secondary fuel filter bracket. Reinstall the two retaining bolts (Figure 8). Tighten the two retaining bolts to 40 Nm (30 Ft. Lb.).

15. Reinstall the large jaw clamp to the left side of the secondary fuel filter (Figure 9). Tighten the retaining nut to 7 Nm (60 In. Lb.).

16. Install the new No. 5 & No. 6 injection line jaw clamp bracket supplied from the kit (Figure 10). Tighten the retaining nut to 18 Nm (13 Ft. Lb.).

17. Place one half of the new injection line jaw clamps, supplied from the kit, onto each of the studs for injection line jaw clamps No. 1 through No. 5 (Figure 1 1 ).

18. Install the new injection lines No. 6 through No. 1 supplied from the kit. Hand tighten the retaining nuts on each end of the new injection line.

19. Place the remaining halves of the new injection line jaw clamps, supplied from the kit, onto each of the studs. Install new retaining nuts, supplied from the kit, onto each of the studs (Figure 12). Tighten the new retaining nuts to 7 Nm (60 In. Lb.).

20. Tighten the retaining nuts on the injection pump end of injection lines No. 6 through No. 1 to 32 Nm (24 Ft. Lb.) each. Tighten the retaining nuts on the injector end of injection lines No. 6 through No. 1 to 32 Nm (24 Ft. Lb.).

21. Lower the cab and reconnect the battery ground cable. Start the engine and check for signs of any fuel leakage from the area of the injection lines. Repair, as necessary.

22. Install the GM 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 by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

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

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

REPAIR PERFORMED PART FAILED PARTS LABOR LABOR COUNT PART NO. ALLOW CC-FC OP HOURS

Install Injection Line Kit 1 --- ** MA-96 V0106 0.9 (Includes Checking For Proper Operation/Fuel Leakage)

* For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 40% for the injection line kit needed to complete the repair.

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

97064

(Sample Of Notification Used)

December, 1997

Dear Chevrolet/GMC Customer:

This notice is sent to inform you of a recall campaign that includes your vehicle.

Reason For This Recall: General Motors has decided that certain 1995-1997 Chevrolet and GMC W5, and 1995-1996 W6 and W7 model vehicles equipped with 6HE1-TC diesel engines, may exhibit a condition in which the fuel injection lines may crack from vibration due to the design of the jaw clamps that hold the injection lines in place. This cracking could cause engine power loss or vibration.

What Will Be Done: To prevent the possibility of this condition occurring, your GM dealer will replace the injection lines, jaw clamps, and other related hardware with new improved parts. This service will be performed for you at no charge.

Contacting Your Dealer: Please contact your GM dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you experience any trouble scheduling your vehicle or you have any questions regarding this recall action, please contact the appropriate Customer Assistance/ Relations Center at the listed number below:

Deaf, Hearing Impaired Division Number or Speech Impaired *

Chevrolet 1-800-222-1020 1-800-833-2438

GMC 1-800-462-8782 1-800-462-8583

* Utilizes Telecommunication Devices for the Deaf/Text Telephones (TDD/TTY)

Customer Reply Card: The enclosed customer reply card identifies your vehicle. Presentation of this card to your GM dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this 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 continued satisfaction with our products.

Chevrolet/Pontiac-GMC Division GENERAL MOTORS CORPORATION

Enclosure

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.