CAMPAIGN: LACK OF ADEQUATE SER./MAINT.-NEW PARTS RELEASED. Pontiac Fiero 1988

For 1990-2009 cars

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

#### Subject: PRODUCT SAFETY CAMPAIGN - 88-C-24A LACK OF ADEQUATE SERVICE OR MAINTENANCE

#### MODELS AFFECTED: 1985-88 PONTIAC FIERO MODELS WITH 2.8L V6 ENGINES (RPO L44) -----------------------------------------------------------------------------

#### TO: ALL PONTIAC DEALERS

"THIS CAMPAIGN BULLETIN SUPERSEDES CAMPAIGN BULLETIN 88-C-24 DATED JUNE 1990. PLEASE DISCARD BULLETIN 88-C-24.

"THIS BULLETIN IS BEING REVISED TO INFORM DEALERS THAT EFFECTIVE WITH CM #206, T-LABOR OPERATIONS CAN ONLY BE USED IN CONJUNCTION WITH V6140 AND V6141 AND ZONE AUTHORIZATION IS REQUIRED FOR ALL T-LABOR OPERATIONS AND V6142."

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 1985-88 Pontiac Fiero Model vehicles with 2.8L V6 engines (RPO L44).

An interaction of the engine compartment environment in 1985-88 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 greatly reduce the possibility of this condition occurring, all vehicles will have changes made in their underhood environment. Specifically, all vehicles will have a manifold deflector installed, a minor change to decklid sealing, a PCV system modification and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally 1985-86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987-88 specifications.

#### VEHICLES INVOLVED

Involved are 1985-88 Pontiac Fiero Model vehicles with 2.8L V6 engine (RPO L44) produced within the following VIN breakpoints:

Up To And Model Year Plant Beginning Including ----- ---- ----- --------- ----------- P 1985 Pontiac FP200001 FP276370

P 1986 Pontiac GP200006 GP283973

P 1987 Pontiac HP200006 HP246579

P 1988 Pontiac JP200003 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 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 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 (1985-86) (ILLUSTRATION A) 10154785 1

Service Kit (1987-88) (ILLUSTRATION B) 10154787 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. Please note also that campaign 86-C-13 "ENGINE SPLASH SHIELDS POTENTIAL INTERFERENCE WITH COOLANT HOSES" should also be done if it is still outstanding.

#### SERVICE PROCEDURE

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 DEFLECTOR

a. Remove outboard grille panels, and disconnect BOTH positive and negative battery cables (remove the battery on vehicles equipped with air conditioning).

b. Remove rear engine compartment lid. Remove rubber dust seal and retaining clips from leading edge (front) of decklid assembly (and leave off) (ILLUSTRATION C).

c. Remove air intake duct assembly (ILLUSTRATION D & E). Remove foam rubber seal on air cleaner housing neck (85-86 only). Remove PCV vent tube elbow(s), clamps and hoses at engine and air cleaner. DO NOT remove PCV vent tube mounted on forward engine compartment wall.

d. Apply penetrating oil to all bolts and studs of the forward exhaust manifold. THIS STEP IS VERY IMPORTANT TO AVOID STUD BREAKAGE LATER ON.

e. Remove exhaust manifold to crossover bolts.

f. Disconnect upper engine strut.

g. Raise vehicle.

h. Remove convertor down pipe to crossover bolts.

i. Remove convertor heat shield.

j. Perform the following steps on air conditioned vehicles:

1. Remove air conditioning compressor shield.

2. Disconnect A/C belt and wires from compressor.

3. Remove A/C compressor mount bolts and lower A/C adjusting bracket.

4. Lower vehicle.

5. Remove upper A/C compressor mount bracket.

6. Raise vehicle.

k. Install jack stands under rear of vehicle to allow cradle to be lowered slightly.

l. Install jack stand under cradle and remove forward cradle bolts and nuts; lower cradle slowly approximately SIX (6) inches below mountings (for better access to front exhaust manifold). Do not lower more than SIX (6) inches.

m. Remove outer exhaust manifold heat shield.

n. Remove forward manifold bolts and studs. Best results will be obtained by:

- Applying penetrating oil early (step c) and reapply now.

- In the event of bolt breakage, a service tool for piloting easy-outs (WITHOUT removing the cylinder head) has been provided. Kent-Moore Tool J-38782 has been provided to all involved dealers.

o. Clear exhaust manifold gasket surfaces. Inspect 1987-88 exhaust manifold for any evidence of cracking or Significant warpage. The 1985-86 vehicles will have a new (slotted flange) manifold installed if not already equipped.

p. Cut wire harness bracket off engine coolant pipe to avoid inter- ference with new shield.

q. Stack manifold deflector, gasket and manifold over new bolts and install (position on head using top bolts) using torque values described in ILLUSTRATION A & B.

r. Modify (ILLUSTRATION F) and install outet manifold heat shield (dimensions for modification on illustration).

s. Reattach cradle and torque cradle bolts according to the applicable Fiero Service Manual procedure. Remove jack stands. Lower vehicle.

t. Install crossover to manifold bolts using torque values described in ILLUSTRATION A & B.

u. Install upper A/C compressor mount bracket.

V. Install side heat shield (A/C equipped vehicles), and install battery (to be connected later).

w. Raise vehicle.

x. Install A/C compressor, attach wires, lower adjusting bracket and belt (do adjustment at this time).

y. Install convertor down pipe to crossover bolts (installing new seal provided in the kit).

z. Install A/C compressor heat shield (A/C equipped vehicles), convertor heat shield.

#### NOTE: THE STEPS BELOW ARE INSPECTION ITEMS. IT IS IMPERATIVE THAT CAPE 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. 1.989) 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.

aa. Conduct inspection underneath the vehicle for:

- Any indication of transmission oil cooler hose leakage.

- Interference between right hard wheelhouse splash shield and coolant hose. IF CAMPAIGN 86-C-13 HAS NOT BEEN PERFORMED, DO IT NOW.

- Any missing heat shield for this application (ILLUSTRATION G).

bb. Lower vehicle. Remove plug wire clip, slide conduit up, and rein- stall clip, connect wires to spark plugs (ILLUSTRATION H). The clip is no longer seated on the bracket arid should be repositioned above the edge of the rocker cover. Bracket should be removed.

cc. Loosen shift cable bracket bolt (already installed on manual trans- mission equipped vehicles; bolt supplied in kit for automatic trans- mission equipped vehicles).

dd. Install new PCV grommet in the forward rocker cover, new air intake duct (w/clamps) and vent tube/bracket assembly. Orient grommet with flat side facing forward (ILLUSTRATION I & J). Position tube/bracket assembly under shift cable bracket bolt (manual transmissions) or install bolt supplied in kit (automatic transmissions). For 1987-88 vehicles, install rubber cap with clamp on air cleaner housing.

ee. Connect engine strut and torque according to the applicable Fiero Service Manual procedure.

ff. Install new oil filler cap on rear rocker cover.

gg. Inspect battery cable and routing for any signs of chafing or wear. Replace or reroute as necessary.

hh. Connect battery and install engine compartment side outer grill.

ii. Install J34730-1 (Fuel Pressure Gauge).

jj. Pressurize fuel system to approximately 40 psi by running fuel pump with key on. Using pressure gage on schrader valve, monitor to check if system holds pressure. Observe coldstart and port injector connections at fuel rail as well as coupled fuel hose fittings for any sign of leakage. Repair as necessary.

kk. Pressurize HOT coolant system to 15 psi. using a hand pump. Observe throttle body heater pipes at connection to throttle body for any signs of leakage. Repair any coolant leakage observed here or elsewhere within the engine compartment.

#### NOTE: STEP 2 IS AN INSPECTION ITEM. IT IS IMPERATIVE THAT CARE BE EXERCISED IN INSPECTION. THE PARTICULAR ITEMS HAVE BEEN CHOSEN DUE TO THEIR POTENTIAL ASSOCIATION WITH UNDERHOOD FIRE.

* 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. INSPECTION -------------- Conduct general inspection of vehicle for any other potential fire related issues, specifically:

- Rocker cover leakage from either gasket surface or PCV valve grommet leakage should be repaired if significant. SEEPAGE IS NOT SIGNIFICANT.

- Improper wiring harness, coolant hose, or fuel line routings which are resulting in chafing of a serious nature should be rerouted (and repaired if necessary).

- Inspect cooling fan operation (on 1985-87 the engine compartment blower fan also should be inspected). Replacement of relay, coolant switch, wiring or fan may be authorized to make functional.

3. Install engine compartment lid.

4. 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 Operation Code Operation Hours Hours --------- ------- --------- ----- ----- Install Deflector Pkg. 96 V6140 3.1 0.1 Vehicle without A/C (1985-88)

Install Deflector Pkg. 96 V6141 5.0 0.1 Vehicle with A/C (1985-88)

Owner Reimbursement On Previous Repairs (ZONE AUTHORIZATION REQUIRED) 96 V6142 --- ---

The labor hours above include time for pressurizing and inspecting the cooling and fuel system.

* In addition, dealership will receive 0.1 hours credit for dealer admini- strative 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 THESE LABOR OPERATIONS.

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 V6140 AND V6141.

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

#### EXHAUST SYSTEM

Zone Labor Labor Authorization Description Hours Operation Required ----------- ----- --------- ------------- Shield Exhaust/Replace .3 T3244 X Each Additional .2 Crossover Pipe .5 T1629 X

#### COOLING SYSTEM

Clamp Radiator 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 Pump/Gasket, Coolant/Replace 2.1 T1630 X Sensor Coolant Temperature .4 T3213 X Coolant Fan Switch/Replace .3 T3215 X Engine Coolant Temp. Switch/Replace .3 T3216 X Thermostat Housing and/or Gasket/Replace .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 Hose, TBI Coolant/Replace .3 T1631 X Relay, Engine Blower .2 T1632 X Motor and/or Fan, Engine Blower .4 T1633 X

#### LUBRICATION SYSTEM

Zone Labor Labor Authorization Description Hours Operation Required ----------- ----- --------- ------------- Rocker Gasket - Right/Rear 2.0 T1634 X Left/Forward 2.3 T1635 X Both 2.6 T1636 X

#### FUEL SYSTEM

Seals, Fuel Feed & Return Pipes .3 T1637 X Pipe, Fuel Pump to Throttle Body Unit/Repl .3 T3312 X Pipe, Fuel/Repair .6 T1626 X O-Ring, Cold Start Valve/Replace 1.0 T1638 X

#### 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

IGNITION SYSTEM/ENGINE COMPARTMENT WIRING ------------------------------------------

Wiring - Pouting/Clips .2 T1627 X

#### BOLT BREAKAGE

Exhaust Manifold (Each Bolt/Stud) .6 T1639 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

Claims for customer reimbursements on previously paid repairs related to ONLY Exhaust Manifold and Exhaust Manifold Fastener Repairs are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation, V6142 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

August, 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 RECALL

General Motors has determined that a defect which relates to motor vehicle safety exists in 1985-88 Pontiac Fiero model vehicles with 2.8L V6 engines.

An interaction of the engine compartment environment in 1985-88 Pontiac Fiero's and maintenance or service related factors results in the potential for engine compartment fire.

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 deflector installed, a minor change to decklid sealing, and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally, 1985-86 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 minimum labor time necessary to perform this service is approximately three. and one/half (3 1/2) 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 your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date, and he does not remedy this condition on that date, or within five days, we recommend you contact the Pontiac Customer Assistance Center by calling: 1-800-762-2737.

After contacting your dealer and the Pontiac Customer Assistance Center, 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, DC 20590 or call 1-800-424-9393 (Washington, DC residents use 366-0123).

The enclosed Campaign Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid Owner 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.