Product Emission 00040 - Fuel System Water Ingestion

General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1998-1999 Chevrolet and GMC P3 model vehicles equipped with a gas engine and having a wheelbase less than 4,039 mm (159 in). Some of these vehicles may have a hard start, no start, or rough running engine caused by water entry into the fuel system through the air inlet separator.

To correct this condition, dealers are to relocate the air inlet separator to eliminate water ingestion.

Involved are certain 1998-1999 Chevrolet and GMC P3 model vehicles equipped with a gas engine and having a wheelbase less than 4, 039 mm (159 in) and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC 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 Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

No parts are required to perform this campaign.

Figure 1 (Photocopy this template)




1. Make a photocopy of the template. Refer to Figure 1.
2. Remove the two 10 mm hex head screws that secure the splash shield to the evaporative emission canister bracket.
3. Discard the splash shield. It will not re-used.
4. Remove the 10 mm hex head screw that hold the air inlet separator to the evaporative emission canister bracket. Reinstall the bolt back into its original location. It will be removed later.
5. Looking at the template, observe the location of the two open centered dots and the one black dot at the right of the template. From inside the evaporative emission canister bracket, insert one of the two 10 mm hex head screws that were removed in Step 2 into the black dot location.
6. Clean the DRIVESHAFT SIDE of the evaporative emission canister bracket as well as the edges to allow adhesion of the template to the bracket.
7. Cut out the two black dots from the template.
8. Place the template to the DRIVESHAFT SIDE of the evaporative emission canister bracket with the open holes in the template over the threads of the two bolts. Tape the template to the bracket.
9. With a center type punch and hammer, place an indentation in the bracket for the new holes at the locations marked with an X on the template.
10. Drill two 6 mm (1/4 in) holes where you have placed the indentation in the bracket.
11. Remove the two 10 mm hex head screws.

Figure 2 (New Orientation of Air Inlet Separator)




12. Install the air inlet separator to the inside of the evaporative emission canister bracket with the locating tabs of the air inlet separator bracket in the two holes that you have drilled (Figure 2).

Tighten
Tighten the 10 mm hex head screw to 8 N·m (71 lb in). (This will orient the air inlet separator toward the rear wheels at a 45 degree angle.)

13. Discard the remaining two 10 mm hex head screws.
14. Install the GM Campaign Identification Label.

For US and IPC

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Materials by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Campaign Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. 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.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP91 when ordering.

Submit a Product Campaign Claim with the information indicated below.

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

FOR US AND CANADA

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

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

FOR IPC

Registered letters will be sent to known owners of record located within areas covered by the U.S. National Traffic and Motor Vehicle Safety Act, as amended. For owners outside these areas, the attached suggested letter is recommended and should be sent by dealers.

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

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 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.

Suggested Dealer Letter

General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1998-1999 Chevrolet and GMC P3 model vehicles equipped with a gas engine and having a wheelbase of less than 4,039 mm (159 in). Some of these vehicles may have a hard start, no start, or rough running engine caused by water entry into the fuel system through the air inlet separator.

We will relocate the air inlet separator to eliminate water ingestion. This service will be performed for you at no charge.

In order 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 if this recall is not accomplished.

We sincerely regret any inconvenience this causes you; however, we have taken this action in the interest of your continued satisfaction with our products.

GMODC

General Motors Corporation

Dear Chevrolet/GMC Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall campaign that includes your vehicle.

General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1998-1999 Chevrolet and GMC P3 model vehicles equipped with a gas engine and having a wheelbase of less than 4,039 mm (159 in). Some of these vehicles may have a hard start, no start, or rough running engine caused by water entry into the fuel system through the air inlet separator.

Your Chevrolet/GMC dealer will relocate the air inlet separator to eliminate water ingestion. This service will be performed for you at no charge .

Please contact your Chevrolet/GMC dealers as soon as possible to arrange a service date. 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.

Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance/Relations Center at the number listed below:

The attached customer reply card identifies your vehicle. Presentation of this card to your 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 card and returning it to us in the postage paid envelope.

In order 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 if this recall is not accomplished.

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