CAMPAIGN: INCORRECT FUEL PUMP IN SENDER UNIT. Chevrolet S10 Pickup

NOTE: GM OF CANADA CAMPAIGN 96056(A) IS LOCATED BELOW THE U.S. VERSION

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: 96056(A) - INCORRECT FUEL PUMP IN SENDER UNIT ---------------------------------------------

MODELS: 1996 4-DOOR 4.3L SIT UTILITIES BUILT AT LINDEN OR MORAINE ---------------------------------------------------------

THIS BULLETIN CANCELS AND REPLACES BULLETIN 96056 ISSUED OCTOBER, 1996. THE SERVICE PROCEDURE HAS BEEN REVISED TO INCLUDE AN ADDITIONAL TEST FOR SUSPECT FUEL PUMPS. ALL COPIES OF BULLETIN 96056 SHOULD BE DESTROYED.

General Motors has decided that certain S/T 4-door Utility model vehicles may have been shipped with the incorrect fuel pump assembled in the fuel sending unit. With the incorrect fuel pump, which has a lower flow rate, the vehicle would exhibit hard starts in cold-start situations and hard starts with lack of power at launch in hot-start situations. These hard starts could be as long as 10-13 seconds and give the customer the impression of a "no-start" condition. Additionally, in hot-start situations, the "Service Engine Soon" light may illuminate and codes be set in the VCM.

To prevent the possibility of this condition occurring, dealers are to perform a test to determine that the correct fuel pump is installed, and replace the fuel pump if it is not.

VEHICLES INVOLVED

Involved are certain 1996 S/T 4-door Utility model vehicles built within the following VIN breakpoints:

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1996 Chevrolet S/T Utility Moraine "2" T2281626 T2282572 1996 Chevrolet S/T Utility Linden "K" TK220699 TK221256 1996 Oldsmobile S/T Utility Moraine "2" T2705146 T2705343 1996 GMC S/T Utility Moraine "2" T2566968 T2567385 1996 GMC S/T Utility Linden "K" TK526716 TK526809

NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) or ServiceNet (GMC only) 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 -------- ------------------------------------- ------------ 25163489 Fuel Sender Assembly (With Fuel Pump) 1 (If Req'd)

CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicles by General Motors (see copy of divisional customer letter(s) included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign mi& 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. Check battery voltage with engine off.

2. If battery voltage is greater than or equal to 12.4 volts proceed to step 4.

3. If battery voltage is less than 12.4 volts run the engine or charge battery.

4. With engine off, connect a 10 AMP meter between battery positive and the fuel pump test lead.

5. If current is greater than 8.2 AMPS the fuel sender has the correct fuel pump. Proceed to Step 7.

6. If current is less than or equal to 8.2 AMPS and sender is suspect, the following secondary test should be conducted:

- Connect a pressure gauge to the Piedmont valve at the fuel metering body.

- With engine running, pinch off the fuel return line near the fuel fuel filter.

- If average pressure is greater than or equal to 80 psi, the correct the correct pump is installed. Proceed to Step 7.

- If the average pressure is less than 80 psi, change the sender. Refer to 4E of the Driveability and Emissions section of the Service Manual.

7. 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 lab provides a space to include the campaign number and the five (5) digit dealer cod 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 install 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 0P HOURS ------------------------- ----- -------- ----- ----- ----- ----- Inspect Only - No Further --- --- --- MA-96 V9961 0.2 Action Required

Inspect and Replace Fuel 1 25163489 ** MA-96 V9962 2.0 Sender Assembly - Vehicles WITHOUT Underbody Shield Package (RPO ZM5)

Inspect and Replace Fuel 1 25163489 ** MA-96 V9963 2.3 Sender Assembly - Vehicles WITH Underbody Shield Package (RPO ZM5)

* 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 fuel sender assembly needed to complete the repair.

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

Dear GM Customer:

As a valued customer, your complete satisfaction with your GM truck is our goal. In keeping with this goal, we want to let you know that we have discovered a problem that could affect your vehicle and we want to take care of it at no charge to you.

In certain 1996 S/T 4-door model vehicles, such as yours, some vehicles may have been shipped with the incorrect fuel pump assembled in the fuel sending unit. With the incorrect fuel pump, which has a lower flow rate, the vehicle would exhibit hard starts in cold-start situations and hard starts with lack of power at launch in hot-start situations. These hard starts could be as long as 10-13 seconds and give the customer the impression of a "no-start" condition. Additionally, in hot-start situations, the "Service Engine Soon" light may illuminate and codes be set in the VCM.

To be absolutely sure that your vehicle is to specifications, your GM dealer will perform a test to determine that the correct fuel pump is installed, and replace the fuel pump if it is not.

Instructions for performing this service have been sent to your GM dealer, and parts are available. Please contact your GM dealer to arrange a service date as soon as possible. This procedure will take approximately 15 minutes to test and 2 hours and 20 minutes to replace the fuel pump, if necessary, but you should ask how much additional time your dealer will need to schedule and process your vehicle.

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.

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

** CANADIAN VERSION **

CUSTOMER SATISFACTION CAMPAIGN

SUBJECT: CAMPAIGN 96056(A) - INCORRECT FUEL PUMP IN SENDER UNIT ------------------------------------------------------

MODELS: 1996 4-DOOR 4.3L S/T UTILITIES BUILT AT LINDEN OR MORAINE ---------------------------------------------------------

DEFECT INVOLVED

General Motors of Canada Limited has decided that certain 1996 S/T 4-door Utility model vehicles may have been shipped with the incorrect fuel pump assembled in the fuel sending unit. With the incorrect fuel pump, which has a lower flow rate, the vehicle would exhibit hard starts in cold-start situations and hard starts with lack of power at launch in hot-start situations. These hard starts could be as long as 10-13 seconds and give the customer the impression of a "no-start" condition. Additionally, in hot-start situations, the "Service Engine Soon" light may illuminate and codes be set in the VCM.

To prevent the possibility of this condition occurring, dealers are to perform a test to determine that the correct fuel pump is installed, and replace the fuel pump if it is not.

VEHICLES INVOLVED

Involved are certain 1996 S/T 4-door Utility model vehicles built within the following VTN breakpoints: PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH ---- --------- ----------- ------- ----- -------- -------- 1996 Chevrolet S/T Utility Moraine "2" T2281626 T2282572 1996 Chevrolet S/T Utility Linden "K" TK220699 TK221256 1996 Oldsmobile S/T Utility Moraine "2" T2705146 T2705343 1996 GMC S/T Utility Moraine "2" T2566968 T2567385 1996 GMC S/T Utility Linden "K" TK526716 TK526809

NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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.

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.

Quantity/ Part Number Description Vehicle ----------- ------------------------------------- --------------- 25163489 Fuel Sender Assembly (With Fuel Pump) 1 (If Required)

CUSTOMER NOTIFICATION

All customers 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 (see copy of customer letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealer's 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.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the campaign coffection has been made before selling or releasing the vehicle.

SERVICE PROCEDURE

1. Check battery voltage with engine off.

2. If battery voltage is greater than or equal to 12.4 volts proceed to step 4.

3. If battery voltage is less than 12.4 volts run the engine or charge battery.

4. With engine off, connect a 10 AMP meter between battery positive and the fuel pump test lead.

5. If current is greater than 8.2 AMPS the fuel sender has the correct fuel pump. Proceed to Step 7.

6. If current is less than or equal to 8.2 AMPS and sender is suspect, the following secondary test should be conducted:

- Connect a pressure gauge to the Piedmont valve at the fuel metering body.

- With engine running, pinch off the fuel retum line near the fuel filter.

- If average pressure is greater than or equal to 80 psi, the correct pump is installed. Proceed to Step 7.

- If the average pressure is less than 80 psi, change the sender. Refer to 4E of the Driveability and Emissions section of the Service Manual.

7. Install 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. Additional Campaign Identification Labels can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 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 LABOUR LABOUR COUNT PART NO. ALLOW CC-FC 0P HOURS ------------------------- ----- ------- ----- ----- ------ ------ Inspect Only - No Further -- --- --- MA-96 V9961 0.2 Action Required

Inspect and Replace Fuel 1 25163489 ** MA-96 V9962 2.0 Sender Assembly - Vehicles WITHOUT Underbody Shield Package (RPO ZM5)

Inspect and Replace Fuel 1 25163489 ** MA-96 V9963 2.3 Sender Assembly - Vehicles WITH Underbody Shield Package (RPO ZM5)

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

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

Refer to the General Motors 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.