CAMPAIGN: INCORRECT ENGINE HARNESS FUSIBLE LINK
SUBJECT: INCORRECT ENGINE HARNESS FUSIBLE LINK
MODELS: 1992 C6/7 TOPKICK/KODIAK TRUCKS WITH GASOLINE ENGINES (LRO/LSO) AND 105/124 AMP ALTERNATORS (K68/KW2)
General Motors has determined that some 1992 C6/7 TopKick/Kodiak medium duty trucks equipped with gasoline engines (LRO/LSO) and 105 amp or 124 amp alternators (K68/KW2), may have been built with engine harnesses containing a larger than specified fusible link. With a larger fusible link, the starter relay circuit and the auxiliary brake pump motor feed circuit may not be properly protected in the event of a "dead short".
To correct this condition, dealers should install a service jumper harness on all affected vehicles.
VEHICLES INVOLVED
Involved are certain 1992 C6/7 TopKick/Kodiak medium duty trucks equipped with gasoline engines (LRO/LSO) and 105 amp or 124 amp alternators (K68/KW2), and built within the following VIN breakpoints:
MODEL YEAR MODEL FROM THROUGH ---- ----- ---- ------- 1992 C6/7 TopKick NJ503559 NJ520752 C6/7 Kodiak NJ104337 NJ105482
The specific vehicles involved in this campaign have been identified by Vehicle Identification Number Computer Listings. These listings are furnished to all involved dealers with the campaign bulletin.
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.
Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin.
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.
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 lefter 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: (Refer to Figure 1) ----------------- 1. Disconnect the negative battery cable.
2. Remove the right hand inner fender.
3. Remove the air cleaner duct.
4. Remove the red wire ring terminal from the generator.
5. Locate the same red wire in the conduit behind the generator and cut the lead to the generator and discard.
6. Unplug the connectors from both the starter relay and the in-line maxi-fuse outlets.
7. Remove the red wire terminals from the starter relay connector (cavity A) and the maxi-fuse in-line connector (cavity A) using Terminal Removal Tool J38125-12 or equivalent.
NOTE: Save the secondary wire locks.
8. Locate these red wires in the conduit and cut the lead to the starter relay and maxi-fuse in-line connector and discard.
9. Disconnect the battery feed terminal to the starter.
10. Locate the battery feed wire in the harness.
11. Cut the lead and discard the starter terminal.
12. Feed the replacement jumper harness down to the starter. Route the jumper harness between the engine harness mounting bracket and the rear of the engine.
NOTE: Do not route harness near exhaust system.
13. Connect the ring terminals to the starter and the generator.
NOTE: The starter ring terminal has two (Red Wire & Fusible Link) wires leading into the ring terminal.
14. Install the shorter female terminal into the starter relay connector (cavity A).
15. Install the longer male terminal into the maxi-fuse in-line connector (cavity A).
16. Replace the secondary locks.
17. Connect Plug into the starter relay and into the maxi-fuse.
18. Attach the jumper harness to the original engine harness by the use of nylon ties in 200mm (approx. 8") increments, wherever possible.
19. Replace air cleaner duct.
20. Replace inner fender.
21. Connect negative battery cable.
22. Start engine to verify electrical function check.
NOTE: "Service Engine Light" should not be on.
23. Install a "Campaign Identification Label".
PARTS INFORMATION
The part required to complete this campaign is to be ordered from Adistra Corporation (313) 455-7658. VIN and dealer code will be required for each part ordered.
DO NOT ORDER PART FOR THIS CAMPAIGN FROM GENERAL MOTORS SERVICE PARTS OPERATION (GMSPO).
Part Quantity/ Number Description Vehicle ------ ----------- --------- 12141054 Replacement Jumper 1 Harness
WARRANTY INFORMATION
Dealers should submit a warranty claim on each vehicle completed under this campaign.
Labor Operation *Time Trouble **Parts Number Description Allowance Code Allowance ------ ----------- ---------- ---- --------- V7670 Install 0.5 hrs. 96 $1.41 Jumper Harness
*For dealer to receive Administrative Time Allowance associated with this campaign, add 0.1 hour to the Labor Operation Time Allowance.
**The $1.41 amount identified in the "Parts Allowance" column above represents 30% of dealer net for the replacement harness's furnished by GMC Truck. This amount is to be placed in the Net Item Amount column of the claim and use type code "M".
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 "GM Truck Claims Processing Manual" #P9119.
COPY OF LETTER TO OWNERS
Dear GM Truck Owner:
Our records show that you own one of our 1992 General Motors TopKick/Kodiak medium trucks. The rate at which these trucks have been accepted into the stream of commerce has been very gratifying to us. In addition, feedback from customers, dealers and our own tracking systems indicate a very high degree of product reliability thus far.
We have recently become aware of a situation where certain 1992 C6/7 TopKick/Kodiak medium duty trucks equipped with gasoline engines (LRO/LSO) and 105 amp or 124 amp alternators (K68/KW2), may have been built with engine harnesses containing a larger than specified fusible link. With a larger fusible link, the starter relay circuit and the auxiliary brake pump motor feed circuit may not be properly protected in the event of a "dead short".
To correct this condition, dealers should install a service jumper harness on all affected vehicles. This service will be completed for you at no charge.
Instructions for performing this service have been sent to your GM TopKick/Kodiak dealer. Please contact your GM TopKick/Kodiak dealer to arrange a service date. Refer to your GM TopKick/Kodiak Servicing Dealers booklet for the dealer nearest you. The labor time necessary to perform this correction is approximately 30 minutes. Please ask your dealer how much additional time will be needed to process your vehicle.
The enclosed postage paid owner reply card identifies your vehicle. Presentation of this card to your GM TopKick/Kodiak 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 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.
GMC TRUCK DIVISION GENERAL MOTORS CORPORATION 92C20 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.
