CAMPAIGN: INCORRECT ENGINE HARNESS FUSIBLE LINK
Subject: INCORRECT ENGINE HARNESS FUSIBLE LINK
Models: 1992 GMC C6/7 TopKick Trucks With Gasoline Engines (RPO LRO/LSO) And 105/124 AMP Alternators (RPO K68/KW2)
TO. ALL GENERAL MOTORS DEALERS:
General Motors of Canada Limited has determined that certain 1992 GMC C6/7 TopKick medium duty trucks equipped with gasoline engines (RPO LRO/LSO) and 105 amp or 124 amp alternators (RPO 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 the following 1992 GMC C6/7 TopKick medium duty trucks.
1GDG6H1PXNJ519299 1GDL7H1PXNJ519198 1GDG6H1P1NJ519224 1GDL7H1P9NJ519435 1GDL6H1P5NJ519631 1GDM7H1M3NJ519330 1GDL7H1MONJ520009 1GDP7H1M3NJ519650 1GDL7H1M4NJ520224 1GDP7H1M9NJ519961 1GDL7H1M4NJ520675 1GDP7H1M9NJ520043 1GDL7H1M9NJ519277
All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.
DEALER CAMPAIGN RESPONSIBILITY:
Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, 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, you are to ensure the campaign correction has been made before selling 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.
CAMPAIGN PROCEDURE:
Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION:
All owners 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 owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION:
Parts required to complete this campaign are being sent directly to dealers by General Motors of Canada on a no charge basis.
Part Number Description Quantity/Vehicle
12141054 Replacement Jumper Harness 1
PARTS AND LABOUR CLAIM INFORMATION:
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:
Repair Code Description Time Allowance
2A Install Jumper Hamess 0.6
Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Repair Code 2A includes $2.00 which represents 30% of the Dealer Net Price for jumper harness.
SERVICE PROCEDURE:
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 fi-om both die 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 J-38125-12 or equivalent. NOTE: Save the secondary wire locks.
8. Locate these red wires in die 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 replacenient jumper harness down to the starter. Route the jumper harness between the engine harness mounting bracket and the rear of die engine.
NOTE: DO NOT ROUTE HARNESS NEAR EXHAUST SYSTEM.
13. Connect the ring terminals to the starter and the generator.
NOTE: 7 1bs starter ring terminal has two (Red Wire and Fusible Link) wires leading into the ring terminal.
14. Install the shorter female termiinal 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 200 mm (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."
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
Dear General Motors Customer:
Our records show that you own one of our 1992 General Motors TopKick medium duty trucks. T'he 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 medium duty trucks, equipped with gasoline engines and 105 amp or 124 amp alternators, 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 your dealer will install a service jumper harness on your vehicle.
This service will be provided for you at no charge.
Please contact your GM dealer as soon as possible to arrange a service date.
If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.
We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
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.
