CAMPAIGN: LACK OF ADEQUATE SER./MAINT.-NEW PARTS RELEASED

Subject: PRODUCT SAFETY CAMPAIGN - 88-C-23A LACK OF ADEQUATE SERVICE OR MAINTENANCE

MODELS AFFECTED 1984-88 PONTIAC FIERO MODELS WITH 2.5L L4 ENGINES (RPO LR8) ----------------------------------------------------------------------------

"THIS CAMPAIGN BULLETIN SUPERSEDES CAMPAIGN BULLETIN 88-C-23 DATED JUNE 1990, AND 84-C-15B DATED MARCH 1989. PLEASE DISCARD BULLETINS 88-C-23 AND 84-C-15B.

"THIS BULLETIN IS BEING REVISED TO INFORM DEALERS THAT AS OF FEBRUARY 1, 1992 CAMPAIGN 84-C-15B IS NO LONGER CONSIDERED NECESSARY DUE TO THE SHIELDS BEING INSTALLED DURING THE CAMPAIGN PROCEDURE AND EFFECTIVE WITH CM #206 ALL T-LABOR OPERATIONS LISTED IN THIS BULLETIN CAN ONLY BE USED IN CONJUNCTION WITH V5990, V5991, V5992 OR 75993 AND ZONE AUTHORIZATION IS REQUIRED FOR ALL T-LABOR OPERATIONS AND V5994."

TO: ALL PONTIAC DEALERS

The National Traffic and Motor Vehicle Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type, must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to adequately repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the owner may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the letter which is being sent to owners, the owners are being instructed to contact the Pontiac Customer Assistance Center if their dealer does not remedy the condition within five days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, owners are instructed on how to contact the National Highway Traffic Safety Administration.

DEFECT INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety exists in 1984-88 Pontiac Fiero Model vehicles with 2.5L L4 engines (RPO LR8).

An interaction of the engine compartment environment in 1984-88 Pontiac Fiero's and maintenance or service related factors results in the potential for engine compartment fires.

If combustible materials come in contact with the exhaust manifold, an engine compartment fire can result. Engine compartment fires can spread to the passenger compartment and cause injury to occupants.

To reduce the possibility of this condition occurring, all vehicles will have changes made in their underhood environment. Specifically, all vehicles will have a manifold barrier installed, a minor change to decklid sealing, and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally, 1984-86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987-88 specifications.

VEHICLES INVOLVED

Involved are certain 1984-88 Pontiac Fiero Model vehicles with 2.5L L4 engines (RPO LR8) produced within the following VIN breakpoints:

Up To And Model Year Plant Beginning Including ----- ---- ----- --------- --------- P 1984 Pontiac EP200001 EP336842

P 1985 Pontiac FP200007 FP276371

P 1986 Pontiac GP200001 GP283974

P 1987 Pontiac HP200001 HP246581

P 1988 Pontiac JP200001 JP226402

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identifica- tion Number, owner name and address data, and are furnished to involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other reason 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. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of owner letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

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.

Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure campaign correction has been made before reselling 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 correction according to instructions contained in this bulletin.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure that these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).

Part Quantity/ Description Number Vehicle ----------- ------ -------- Service Kit (1984-85-86) (ILLUSTRATION A) 10184936 1 Service Kit (1987) (ILLUSTRATION B) 10184937 1 Service Kit (1988) (ILLUSTRATION C) 10184938 1

Breakdown of the specific parts included in these kits are shown on the applicable illustrations.

Additional parts necessary to correct engine compartment fluid leaks, or cooling system discrepancies, etc., are to be ordered from GMSPO as required from the appropriate service parts catalog.

NOTE: The following parts cannot be ordered from GMSPO; dealers should contact the zone if additional parts are needed.

Part Quantity/ Description Number Vehicle ----------- ------ --------- "Check Engine Oil At Every Fill" Label NPN 1

"Engine Coolant System Fill Procedure" Label 10030499 1

Revised 1984 Fiero Maintenance Schedule Booklet 10077793 1

Supplement To 1984 Fiero Owners Manual - Page 5-8 10077794 1

Supplement To 1984 Fiero Owners Manual - Page 6-4 10077795 1

Check Oil Reminder Label 10125898 1

Supplement To 1985 Owners Manual 10122627 1 10122628 1

Supplement To 1986 Owners Manual 10122629 1

Supplement To 1987 Owners Manual 10122630 1 10122631 1

SERVICE PROCEDURE

NOTICE: The "Check Oil" reminder label and/or glove box supplements listed under the Parts Section of this Campaign should be taken care of at this time if they are they do not appear on the car or in the glove box.

To reduce the effects of fluid leaks which may lead to engine compartment fires, Pontiac dealers will do the following at no charge:

1. INSTALL EXHAUST MANIFOLD SHIELD

a. Remove right side grille panel & disconnect negative battery cable.

b. Remove rear engine compartment lid (on 1984 models also remove center grille from engine compartment lid). Remove rubber dust seal and retaining clips (rivets) from leading edge (front) of decklid assembly (and leave off). On 1984 vehicles, remove plastic deflector from underside of decklid grille opening (and leave off); reinstall center grille. (See Illustration D for component identification.)

C. Remove air cleaner assembly.

d. Remove dipstick tube.

e. Disconnect 02 sensor wire.

f. Raise vehicle.

g. Remove and discard convertor splash shields (only on 1984-85).

h. Remove convertor pipe to exhaust manifold bolts.

i. Remove A/C mount bracket bolt and install new stud-headed bolt (#3) in block above oil pan rail at A/C bracket. Spacer (1984-86: #4 - WITHOUT A/C or NO Spacer WITH A/C; 1987 & 88: #4 - WITHOUT A/C or #26 - WITH A/C) to be installed on stud.

j. Lower vehicle.

k. Remove exhaust manifold and gasket.

l. Clean gasket surface on cylinder head and exhaust manifold if a new manifold is not installed.

m. Install protective tape wrap (provided in kit) on engine wiring harness starting at thermostat housing and ending at bulkhead connector on 1984 vehicles (Illustration 9).

n. Install new cylinder head bolts (1984-86 vehicles only) provided in kits. New cylinder head bolts should be installed using torque values described in Illustration A & B. HEAD BOLTS SHOULD BE REPLACED ONE AT A TIME. If a broken head bolt is encountered, refer to Dealer Service Bulletin 87-6(GAS)-94 for the proper procedure.

o. Install new 02 sensor (#21, 1984-86) in exhaust manifold.

p. Install deflector (#2), gasket (#23), and exhaust manifold (#7) (new manifold provided for 84-86 vehicles). Shield is not gasketed against cylinder head. Note that shield leg/bracket has different spacers (#4 or #26) or no spacer depending upon model year and equipment.

q. Manifold bolts should be installed using torque values described in Illustration A, B & C. Lock tabs (#6, 1984-88) should be installed on outboard manifold runner bolts.

r. Install dipstick tube.

s. Install new exhaust pipe seal. Loosely install one (1) convertor pipe to exhaust manifold bolt (#12).

t. Raise vehicle.

u. Install remaining manifold to convertor pipe bolt (#12) and tighten using torque values described in Illustration A & B.

v. Install shield leg nut (#5) and washer (#19) and tighten using torque values described in Illustration A, B & C.

w. Lower vehicle.

x. Remove starter motor heat shield and clamps (may already be removed) from exhaust manifold to convertor exhaust pipe.

y. Install new heat stove (#20 & 25, 1984-86 only) as shown in Illustra- tion A with band clamps (#20) on front pipes.

z. Install air cleaner assembly.

aa. Connect negative battery cable and install right side grille panel.

NOTE: THE REMAINING STEPS BELOW ARE INSPECTION ITEMS. IT IS IMPERATIVE THAT CARE BE EXERCISED IN INSPECTION. THE PARTICULAR ITEMS HAVE BEEN CHOSEN DUE TO THEIR POTENTIAL ASSOCIATION WITH UNDERHOOD FIRE.

* PRIOR TO PERFORMING THESE INSPECTIONS, THE TRAINING VIDEO "WINNERS DO IT RIGHT" (MAILED SEPT. 1989) SHOULD BE VIEWED.

* PLEASE NOTIFY YOUR CUSTOMER OF ANY ISSUES NOT FIXED IN YOUR INSPECTION WHICH WILL BE HIS/HER RESPONSIBILITY.

* ALL INSPECTION ITEMS REQUIRE ZONE AUTHORIZATION.

2. INSPECT COOLING SYSTEM

a. Visual check of coolant level Adding needed coolant to specified level and/or diagnostic procedure may be authorized if coolant loss is determined to be a chronic problem.

NOTE: With engine cold, perform a pressurized leak test as described in 1986 Fiero Service Manual Section 6B-14, 15.

b. Visually inspect for significant leaks. Repairs may be authorized for external coolant leaks from any engine compartment area, specifically thermostat housing, water pump, coolant hoses and connectors in engine compartment.

c. Visually inspect for signs of coolant hose wear or aging. Replacement of damaged hoses may be authorized.

d. Perform a function check of cooling fan. Replacement of relay, coolant switch, wiring or fan may be authorized to make functional.

3. INSPECT EXHAUST SYSTEM

a. Observe for any significant leaks (vehicle running). Repairs may be authorized for any leaks forward of the catalytic convertor. Also repairs should be made if any irregularity in manifold or front pipe revents proper installation of the new shield.

b. Visually inspect for presence of appropriate heat shields. Repair or replacement may be authorized for starter shield, convertor shield, muffler shield, or bulkhead shields. See Illustrations F and G for correct configurations.

4. INSPECT LUBRICATION SYSTEM

a. Visually inspect for indications of significant oil leakage. Repairs for seepage will not be authorized, only areas with significant leakage. Specifically, rocker cover gasket repair or PCV breather may be authorized. Oil pan or filter leaks are not normally covered.

b. Visually verify update to 4 quart system. Vehicles should all be equipped with the larger oil filter (PF51 style). Replacement of the filter may be authorized if vehicle was not previously retrofit.

c. Check oil level. Make-up oil may be authorized for vehicles 1 quart or more low.

5. INSPECT FUEL SYSTEM

a. Visually inspect for signs of leakage inside engine compartment. Repairs may be authorized for retorque, new fitting, or hose replace- ment.

b. Visually inspect evaporative emission system for integrity of harness connections. Reinstallation of harness may be authorized. Tampered systems to be replaced only if vapor lines were left open (presenting some fire risk). All emission discrepancies should be noted in writing to the owner and noted on the repair order.

6. INSPECT TRANSMISSION OIL COOLER

a. Visually inspect for signs of oil cooler hose leakage near trans- mission. Repairs may be authorized for hose degradation or fitting tighten/replace.

7. INSPECT IGNITION SYSTEM

a. Visually inspect for proper spark plug wire routing. Rerouting may be authorized if required and replacement of spark plug wire retainer clips only.

8. INSPECT ENGINE COMPARTMENT WIRING

a. Visually inspect for correct routing of engine wiring harness in vicinity of exhaust manifold. Reroute and clip as necessary.

b. Visually inspect for correct battery cable routing. Reroute and clip if required.

c. Visually inspect for any obvious chafing/wear on starting/charging circuit wiring. Wire, conduit or retainer replacement may be authorized if necessary.

9. VISUALLY INSPECT FOR ANY COMBUSTIBLE MATERIALS HANGING LOOSE IN FRONT OF ENGINE COMPARTMENT. (e.g. conduit, insulation) Remove as required.

10. Install rear engine compartment lid and left side grille panel.

NOTE THAT COMPONENTS ON THE BULKHEAD WILL NOW BE BARELY VISIBLE FROM OUTSIDE THE VEHICLE WITH THE ENGINE COMPARTMENT LID CLOSED. THIS CHANGE INCREASES AIR FLOW THROUGH THE ENGINE COMPARTMENT. SHOULD YOUR CUSTOMER WISH, THE VISIBLE BULKHEAD COMPONENTS MAY BE SPRAYED FLAT BLACK.

11. 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, the five (5) digit dealer code of the dealer performing the campaign service and the date the vehicle was campaigned. This information may be inserted with a typewriter or a ball point pen. Install the label only on underside of decklid where it is readily visible (additional campaign labels are available on stationary order as Form 7901-709).

CLAIM INFORMATION

A separate repair order must be kept for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Install shield kit (1984) 96 V5990 3.0 0.1

Install shield kit (1985-86) 96 V5991 2.5 0.1

Install shield kit (1987) 96 V5992 2.4 0.1

Install shield kit (1988) 96 V5993 2.3 0.1

Owner Reimbursement On Previous Repairs (ZONE AUTHORIZATION REQUIRED) 96 V5994

* In addition, dealership will receive 0.1 hours credit for dealer administrative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH THIS LABOR OPERATION.

IF THE INSPECTION PROCEDURE REVEALS ADDITIONAL OPERATIONS ARE NECESSARY, THE APPROPRIATE T-LABOR OPERATIONS SHOULD BE SELECTED FROM FOLLOWING CHARTS. THESE CAN ONLY BE USED IN CONJUNCTION WITH V5990, V5991, V5992 OR V5993.

NOTICE: FAILURE CODE 95 MUST BE USED WITH ANY OF THE FOLLOWING T-LABOR OPERATIONS IN CONJUNCTION WITH ZONE AUTHORIZATION.

- 2 - COOLING SYSTEM

Zone Labor Labor Authorization Description Hours Operation Required ----------- ----- --------- ------------- Clamp Rad. Hose - Replace .2 T3203 X Add: To Replace Each Addt'l. .1 Coolant Hoses Replace Upper .6 T3204 X Coolant Hoses Replace Lower .6 T3205 X Replace Both Upper & Lower 1.0 T3206 X Coolant Pump Inlet - Replace .7 T3207 X Pump/Gasket Coolant Replace 2.0 T3209 X Sensor Coolant Temp. .4 T3213 X Coolant Fan Switch/Replace .3 T3215 X Engine Coolant Temp. Switch/Replace .3 T3216 X Thermostat Housing and/or Gasket .4 T3242 X Heater Pipe Clamp - Replace .3 T3229 X Hose, Htr. Pipe to Eng. Comp. Inlet/Repl. .4 T3232 X Hose, Eng. Comp. Inlet to Engine/Repl. .4 T3233 X Hose, Htr. Pipe to Engine Outlet/Repl. .4 T3234 X Blade/Motor Cooling Fan/Replace .6 T3235 X Relay, Cooling Fan Replace .3 T3236 X Wiring and/or Connector/Repair .5 T3237 X Gasket, Cylinder Head 3.3 T3218 X

- 3 - EXHAUST SYSTEM

Shield Exhaust/Replace .3 T3244 X Each Additional .2 Front Exhaust Pipe .7 T1625 X (Manifold to Convertor)

- 4- LUBRICATION SYSTEM

Zone Labor Labor Authorization Description Hours Operation Required ----------- ----- --------- ------------ Rocker Gasket .5 T3172 X Cap Oil Filler Replace .2 T3220 X Crankcase Ventilation Grommet .2 T3227 X

- 5 - FUEL SYSTEM

Nut/Gasket Fuel Inlet or Outlet Replace .3 T3211 X Pipe Fuel Pump to Throttle Body Unit/Repl .3 T3212 X Pipe Fuel Repair .6 T1626 X

- 6 - TRANSMISSION OIL COOLER

Upper Trans. Oil Cooler Hose Replace .2 T3180 X Lower Trans. Oil Cooler Hose Replace .2 T3181 X Both Trans. Oil Cooler Hose Replace .3 T3182 X

- 7/8 - IGNITION SYSTEM/ENGINE COMPARTMENT WIRING

Wiring - Routing/Clips .2 T1627 X

BOLT BREAKAGE

Broken Cylinder Head Bolt (1) .2 T1628 X

Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the proper labor operation as outlined.

REIMBURSEMENTS

Customer claims for reimbursement on previously paid repairs related ONLY to Broken Head Bolts and/or Engine Compartment Cooling System Leaks are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation, V5994 which requires zone authorization, listed under the Claim Information Section of this bulletin. Reimbursement amounts of $300.00 or less can be processed by the dealer. If the amount exceeds $300.00 an Owner Reimbursement Form 7201-039 must be forwarded to and processed by the Zone Office.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in this campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

Notification Used by Pontiac

October, 1990

Dear Pontiac Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

REASON FOR THE RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in 1984-88 Pontiac Fiero Model vehicles with 2.5L 4 cylinder engines.

An interaction of the engine compartment environment in 1984-88 Pontiac Fiero's and maintenance or service related factors results in the potential for engine compartment fires.

If combustible materials come in contact with the exhaust manifold, an engine compartment fire can result. Engine compartment fires can spread to the passenger compartment and cause injury to occupants.

WHAT WE WILL DO

To reduce the possibility of this condition occurring, all vehicles will have changes made in their underhood environment. Specifically, all vehicles will have a manifold barrier installed, a minor change to decklid sealing, and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally, 1984-86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987-88 specifications.

This service will be performed for you at no charge.

WHAT YOU SHOULD DO

Please contact your Pontiac dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. The labor time necessary to perform this service inspection/correction is approximately two (2) to three (3) hours. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

Your Pontiac dealer is best equipped to obtain parts and provide service to ensure that your vehicle is corrected as promptly as possible. If, however, you take your vehicle to your dealer on the agreed service date and they do not remedy this condition on that date or within five (5) days, we recommend you contact the Customer Assistance Department, Pontiac Home Office, by calling 1-800-762-2737.

After calling the Customer Assistance Center and the Pontiac Home Office, if you are still not satisfied that we have done our best to remedy this condition without charge, within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, S.W., Washington, D.C. 20590, or call 1-800-424-9393 (Washington D.C. residents use 366-0123).

The enclosed owner reply card identifies your Pontiac vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/ correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

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.