CAMPAIGN: ANTI-LOCK BRAKE PRESSURE WARNING LIGHT. Pontiac 6000 1986

For 1990-2009 cars

# CAMPAIGN: ANTI-LOCK BRAKE PRESSURE WARNING LIGHT

#### VEHICLES AFFECTED: 1986-1987 Pontiac 6000, STE Models, Equipped With Anti-Lock Brake System

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 owners 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 owner's, the owner's are being instructed to contact the nearest 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, they are instructed on how to contact the National Highway Safety Administration.

#### CONDITION INVOLVED

General Motors has determined that a defect which relates to motor vehicle safety may exist in some 1986 and 1987 Pontiac 6000, STE models, equipped with Anti-Lock Brake System (ABS).

Involved 1986 model year vehicles may exhibit brake fluid seepage from the ABS pressure/warning switch which eventually can lead to loss of the brake system hydraulic pump motor. Additionally, on both 1986 and 1987 involved vehicles, the hydraulic pump motor and ABS electrical relays may have been exposed to water contamination during vehicle assembly. This condition can cause loss of the hydraulic pump motor and/or loss of the ABS function.

Loss of the hydraulic pump motor would, after accumulated pressure has been depleted (approximately 10-30 normal stops), result in a total loss of rear brakes as well as power assist to the front brakes. The red "Brake" warning light would, before accumulated pressure has been depleted, illuminate and stay ON. If this warning is not heeded, a loss of rear brakes at a time when minimum stopping distance is required could result in a vehicle crash.

An inoperative ABS electrical relay could cause loss of the ABS function, but normal power assisted braking would be retained. The amber "Anti-Lock" warning light would illuminate and stay ON.

To correct these conditions, on 1987 model year vehicles, both the ABS and hydraulic pump motor relays will be replaced. On 1986 model year vehicles, both the ABS and hydraulic pump motor relays and 30 amp fuses will be replaced. In addition, on 1986 models, the hydraulic pump motor assembly and pressure/warning switch will be inspected and, if required, replaced.

#### VEHICLES INVOLVED

Involved are certain 1986-1987 Pontiac 6000, STE models, equipped with Anti-Lock Brake System (ABS) within the following breakpoints:

YEAR PLANT FROM THROUGH ---- ----- ---- ------- 1986 Oshawa G9238623 G9323920

1987 Oshawa Six (6) vehicles listed as follows:

H9200162 NOTE: The 1987 model year H9200514 vehicles listed require H9200643 relay replacement only. H9200647 H9201003 H9201041

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the 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 purpose 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 Letters 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 the 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 modification according to instructions contained in this bulletin.

#### PARTS INFORMATION

Parts required to complete this modification are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure 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 NUMBER DESCRIPTION QUANTITY/VEHICLE

12040835 Relay 2

12004011 30 Amp Fuse 2

25530882 Pressure/Warning I - As Required Switch

25528401 Hydraulic Pump 1 - As Required and Motor Assy.

It is anticipated that most vehicles will require a pressure/warning switch, but less than 20% will require a hydraulic pump and motor. Please adjust your orders accordingly for the hydraulic pump and motor assembly.

SERVICE PROCEDURE

1986 AND 1987 MODEL YEAR VEHICLES

1. Disconnect negative battery cable.

2. Remove two (2) relay assemblies (P/N 12040835) from their respective brackets (See figures 1,2 & 3) and disconnect from electrical harness.

3. Reconnect electrical harness to new relay assemblies and install in original position. Torque bolts/screws to 3-4 N.m. (27-35 lbs.in.)

RELAYS MUST BE INSTALLED WITH CONNECTOR AT BOTTOM TO PREVENT WATER ENTRY.

1986 MODEL YEAR VEHICLES ONLY

4. Replace both the pump motor 30 amp fuse and the ABS 30 amp main fuse (See figures 2 and 3).

#### CAUTION:

FAILURE TO FULLY DEPRESSURIZE THE HYDRAULIC ACCUMULATOR BEFORE PERFORMING SERVICE OPERATIONS COULD RESULT IN INJURY TO SERVICE PERSONNEL AND DAMAGE TO PAINTED SURFACES.

5. Visually inspect hydraulic pump and motor housing for any evidence of brake fluid see page below pressure/warning switch. If any components require replacement, care should be taken to prevent brake fluid spillage onto motor (See figure 5).

A. If any evidence of brake fluid seepage is indicated, perform following steps as indicated in the 1987 Pontiac 6000 Service Manual pages 5E - 5,6 & 7. If no seepage is indicated, proceed to step 5B.

1. Replace hydraulic pump and motor assebmly.

2. Inspect pressure/warning switch for red plastic identification band (See figure 4). If red band is observed, switch requires replacement. If red band is not observed, original switch must be transferred to replacement pump and motor assembly.

B. If there is no evidence of brake fluid seepage, inspect only pressure/warning switch for red plastic identification band (See figure 4). If red band is observed, switch requires replacement. Follow pressure switch replacement procedure in 1987 Pontiac Service Manual page 5E - 7. If red band is not observed, proceed to step 5C.

C. If visual inspection does not indicate any parts replacement except for relay and fuses (as applicable) replaced in steps 2 - 3, reconnect battery cable and proceed to step 7.

6. If pressure/warning switch is replaced, without pump and motor assembly replacement; check fluid level in reservoir and ensure that it is filled to the mark. DO NOT OVERFILL OR UNDERFILL. Reconnect battery cable and turn ignition key to ON position until pump motor stops. Check for brake fluid leak.

NOTE- Use only DOT 3 brake fluid from a clean, sealed container. Do not use fluid from a container which is wet with water. Use of Dot 5 silicone fluid is not recommended. Internal damage to pump components may result.

If hydraulic pump motor assembly is replaced:

A. Fill reservoir with brake fluid. Connect battery cable.

B. Turn ignition key to ON position until pump motor stops.

C. Check for brake fluid leak.

D. Turn ignition key to OFF position and discharge accumulator. See Checking and Filling in 1987 Pontiac Service Manual page 5E - 3.

E. Ensure that the brake fluid resevoir is filled to the mark. Do not overfill or underfill.

1986 AND 1987 MODEL YEAR VEHICLES

7. Install Campaign Identification Label

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified 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 digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as. Form 7901-709).

#### CLAIM INFORMATION

A separate repair order must be used 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 NET** OPERATION CODE OPERATION HOURS HOURS AMOUNT --------- ------- --------- ----- ----- ------ Inspect & Install: 96 V4050 0.3 0.1 --- (1987 Models Only) 2-Relays

Inspect & Install: 96 V4051 0.3 0.1 --- (1986 Models Only) 2-Relays 2-30 Amp Fuses

Inspect & Install: 96 V4052 0.4 0.1 $1.00 (1986 Models Only) 2-Relays 2-30 Amp Fuses 1-Pressure/Warning Switch

Inspect & Install: 96 V4053 0.6 0.1 $2.86 (1986 Models Only) 2-Relays 2-30 Amp Fuses 1-Hydraulic Pump & Motor Assy.

Inspect & Install: 96 V4054 0.7 0.1 $2.86 (1986 Models Only) 2-Relays 2-30 Amp Fuses I-Pressure/Warning Switch 1-Hydraulic Pump & Motor Assy.

* In addition dealerships 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.

** The amounts shown in the "Net Amount" column represent allowance for Dot 3 brake fluid used in conjunction with the described operations and must be entered in the net items column of the warranty claim.

#### FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance.

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

#### 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.

SERVICE DEPARTMENT PONTIAC DIVISION GENERAL MOTORS CORPORATION

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.