For 1990-2009 cars

# CAMPAIGN: PRODUCT SAFETY FRT. FUEL FEED HOSE ASSEMBLY

#### SUBJECT: FRONT FUEL FEED HOSE ASSEMBLY

#### MODELS: Certain 1988 and 1989 Cutlass Calais, Grand Am, Skylark Model Vehicles with Quad 4 Engines (RPO LD2; VIN Code D)

#### TO: ALL GENERAL MOTORS DEALERS

#### NOTICE: THIS SAFETY RECALL HAS BEEN EXPANDED (SEE REVISED "VEHICLES INVOLVED" SECTION). ALSO, AN "IMPORTANT" NOTE HAS BEEN ADDED TO THE SERVICE PROCEDURE AT STEP 5. THIS BULLETIN CANCELS AND SUPERSEDES PRODUCT CAMPAIGN BULLETIN OA18, WHICH SHOULD BE DISCARDED.

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1988 and 1989 Oldsmobile Cudass Calais, Pontiac Grand Am and Buick Skylark model vehicles equipped with Quad 4 engines (RPO LD2; VIN Code D). The Front Fuel Feed Hose Assembly could crack or separate at the coupling on the engine end of the hose assembly, allowing fuel to leak into the underhood area. Under certain circumstances, this could result in an underhood fire.

To prevent this condition from occurring, dealers are to inspect, and if required, replace the Front Fuel Feed Hose Assembly on involved vehicles.

#### VEHICLES INVOLVED:

PLEASE CHECK DCS BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

Certain 1988 and 1989 Oldsmobile Cutlass Calais, Pontiac Grand Am and Buick Skylark model vehicles equipped with Quad 4 engines (RPO LD2; VIN Code D) within the breakpoints listed below:

Year Model Beginning Through & Including ---- ----- --------- ------------------- 1988 Cutlass Calais JM248891 JM277820 1988 Grand Am JC705630 JC771622 1988 Skylark JM027965 JM036481 1989 Cutlass Calais KM220636 KM309890 1989 Grand Am KC641527 KC846424 1989 Skylark KM008754 KM061525

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 kilometres traveled, 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, you are to ensure the campaign correction has been made before selling 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.

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 with this bulletin). The listings provided are for campaign activity only and 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 ----------- ----------- ---------------- 24570910 Pipe, Fuel Injection Fuel Feed 1, As Required (Front Fuel Feed Hose Assembly)

PART NUMBERS ARE LISTED BELOW FOR THOSE RARE CASES IN WHICH O-RINGS OR RETAINERS MAY BE LOST OR DAMAGED DURING REMOVAL OF THE FUEL FEED HOSE:

Description Part Number Colour Quantity/Vehicle ----------- ----------- ------ ---------------- O-Ring Seal, at Fuel Rail 17075389 Black As Required Retainer, O-Ring, Fuel Rail 17081403 White As Required O-Ring Seal, at Body Pipe 22514722 Brown As Required

#### 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 for Presence of P/N 24570910 .3 Hose, Only

2A Inspect for Correct Hose and Replace .4 Hose Assembly

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

#### SERVICE PROCEDURE:

1. Raise and support the hood. Examine the Front Fuel Feed Hose Assembly. If the hose assembly is P/N 24570910 part, as shown in Figure 1, proceed directly to Step 9. Otherwise, proceed to Step 2.

2. Note owner's radio station choices, then disconnect negative battery cable and remove fuel tank filler cap.

3. Relieve pressure in fuel system following instructions below:

#### CAUTION:

To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before servicing fuel system components, otherwise fuel spray could occur. Have a dry chemical (Class B) fire extinguisher near the work area.

A. Connect fuel gauge J-34430-1 or equivalent to fuel pressure connection. Wrap a shop cloth around fitting while connecting gauge to collect fuel. Then place cloth in an approved container.

B. Install bleed hose into the approved container and open valve to bleed system pressure. Drain any fuel remaining in the gauge into an approved container.

4. Disconnect Front Fuel Feed Hose at engine and body fuel feed pipes utilizing a backup wrench on fittings. Take care not to lose the seal and washer at the fuel rail. Remove bolt and pipe clamp on engine.

5. Examine the O-ring seal and the white plastic (washer) retainer in the end of the fuel rail; determine that they are undamaged and in proper position for reuse. Examine the O-ring on the body fuel feed pipe, making sure O-ring is in proper position and undamaged for reuse. See Figure 2.

#### IMPORTANT: When the Front Fuel Feed hose/pipe fitting is disconnected at the Fuel Rail, there are two ways in which the retainer (white plastic washer) may be moved out of position: If the pipe is cocked while being withdrawn from the fuel rail, the retainer may be cocked or pulled slightly out. Also, the weight of the fuel in the fuel rail may push the retainer out of position when the fuel feed hose/pipe is withdrawn. If the new Front Fuel Feed Hose is installed without first ensuring the retainer is correctly positioned (square and fully seated), the connection may leak.

6. Obtain new Front Fuel Feed Hose (Service P/N 24570910). Install the new Front Fuel Feed Hose to the engine fuel rail and to the body fuel feed pipe fitting, ensuring hose is not kinked or twisted. Torque the pipe nut at the fuel rail to 30 N.m (22 lbs. ft.) and the hose fitting at the body pipe to 27 N.m (20 lbs. ft.), utilizing a backup wrench on fittings.

Reinstall bolt and pipe clamp, torquing bolt to 12 N.m (106 lbs. in.).

Ensure that there is at least 13mm (1/2 inch) clearance between the fuel feed hose and any sharp edges. Do likewise for the fuel return hose assembly.

7. Reinstall fuel tank filler cap and reconnect the negative battery cable. Reset clock and radio station preset buttons to owner's choices noted at Step 2.

8. Start engine and check for possible fuel leaks and correct as required. Also check the fuel pressure connection for leaks.

9. Install a 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 inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

General Motors of Canada Limited has determined that a defect which relates to motor vehicle safety exists in certain 1988 and 1989 Oldsmobile Cutlass Calais, Pontiac Grand Am and Buick Skylark model vehicles equipped with Quad 4 engines. The Front Fuel Feed Hose Assembly could crack or separate at die coupling on the engine end of the hose assembly, allowing fuel to leak into the underhood area. Under certain circumstances, this could result in an underhood fire.

To prevent this condition from occurring on your vehicle, we will inspect, and if required, replace the hose assembly. This service will be provided for you at no charge.

Even if you believe your vehicle was previously repaired for the above described condition, please contact your dealer. Your dealer may need to inspect your vehicle to ensure it has the correct part installed.

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.