CAMPAIGN:FUEL TANK FILL PIPE TO VENT TUBE ATTACHMENT. GMC Truck S15 Pickup

SUBJECT: FUEL TANK FILL PIPE TO VENT TUBE ATTACHMENT

MODELS: 1994 Chevrolet S-10 Pickups and GMC Sonomas

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1994 Chevrolet S-10 Pickups and GMC Sonomas fail to conform to Canada Motor Vehicle Safety Standards (CMVSS) 301, "Fuel System Integrity". These pickups may have been shipped with fuel tank filler pipe assemblies that were not manufactured by the supplier to GM specifications. With the out-of-specification fill pipe assembly, a vehicle tested to the requirements of (CMVSS) 301 may leak fuel in excess of the amount permitted by the Standard, from the joint between the fuel tank filler pipe and the vent tube. If a vehicle crash were to occur causing this joint to crack and if the vehicle overturned, fuel leakage could possibly occur which could result in a post-crash fire.

To correct this condition, dealers are to replace the fuel filler pipe on involved vehicles.

VEHICLES INVOLVED:

Involved are certain 1994 Chevrolet S-10 Pickups and GMC Sonomas built within the following VIN breakpoints:

Year Model Plant Plant Code From Through

1994 Chevrolet S-10 Linden K SOP RK139607 1994 Chevrolet S-10 Shreveport 8 SOP R8158226 1994 GMC Sonoma Linden K SOP RK512262

1994 GMC Sonoma Shreveport 8 SOP R8512911

NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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

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 owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used 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.

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 should not be used for any other purpose.

PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ---------------------------------------------------------------------------- 15648274 Fuel Tank Filler Pipe Assembly 1

11509087 (Or equivalent) Plastic Strap 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

1A Inspect Vehicle for Blue Dot and install .3 Campaign Label

2A Inspect Vehicle for Blue Dot and .6 replace Fuel Tank Filler Pipe

7A Fuel Top-Off .5 Wash Vehicle

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 40% to cover parts handling.

SERVICE PROCEDURE:

INSPECTION

Visually inspect the inside rear view mirror glass to see if there is a 3/4" diameter round blue sticker there. If the sticker is present, the vehicle has been repaired at the assembly plant and does not require replacement of the fuel filler pipe. A Campaign Identification Label must be installed.

If no blue sticker is present, the fuel tank filler pipe must be replaced following the "REPLACEMENT" PROCEDURE" which follows.

REPLACEMENT PROCEDURE

CAUTION:

Gasoline and gasoline vapors are highly flammable. If an ignition source is present, a fire could occur. Have a dry chemical (Class B) fire extinguisher near by.

NOTICE: Fuel level must be below 3/4 of a tank before proceeding with this procedure. If the fuel level is not below 3/4 follow the normal service procedures for removal of fuel from the fuel tank.

1. Open fuel filler door and remove cap.

2. Remove 3 filler pipe attaching bolts.

3. Raise vehicle.

4. Remove fuel filler pipe ground strap and fuel tank sending unit ground strap retaining bolt at frame.

5. Remove plastic strap retaining canister hose to filler pipe.

6. Disconnect fuel filler hose from filler pipe.

7. Disconnect fuel tank vent hose from vent tube on filler pipe.

8. Remove filler pipe.

9. Install new filler pipe.

10. Reconnect fuel tank vent hose on filler pipe.

11. Reconnect fuel filler pipe to fuel filler hose.

12. Install new plastic strap to retain canister hose to filler pipe.

13. Install filler pipe ground strap and fuel tank sending unit ground strap retaining bolt at frame. Torque bolt to 18 N.m (13 lb. ft).

14. Lower vehicle.

15. Install fuel filler pipe attaching screws and torque to 2.2 N.m (20 lb. in.).

16. Install fuel cap and close filler door.

17. If fuel was drained from vehicle to bring level down to 3/4, add fuel to return to original level.

18. Install 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 on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer.

To correct this condition, your dealer will replace the fuel filler pipe on involved vehicles.

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.