For 1990-2009 cars

# CAMPAIGN: FUEL FEED AND RETURN HOSE/PIPE ASSEMBLIES

#### Models: 1987 Calais, Grand Am, Somerset with L68 and MT2

#### TO: ALL GENERAL MOTORS DEALERS

#### DEFECT INVOLVED:

General Motors of Canada has determined that a defect which relates to motor vehicle safety may exist in some 1987 Calais, Grand Am and Somerset Models equipped with 2.5L engines and five-speed manual transaxles. The fuel feed or fuel return hose at the engine may rub against a shift lever on the 5-speed transaxle. With time, a hole could be rubbed through the hose and fuel could leak into the engine compartment. Under certain circumstances, this could result in an underhood fire.

Dealers are to replace the Fuel Feed and Return Hose/Pipe Assemblies.

#### VEHICLES INVOLVED:

Certain 1987 Oldsmobile Calais, Pontiac Grand Am and Buick Somerset Models equipped with 2.5L L68 (VIN Code U) engines and MT2 Five-speed Manual Transaxles within the following vehicle breakpoints:

#### Model From Through ----- ---- ------- Grand Am HC700001 HC917871

Calais HM200001 HM307145

Somerset HM000001 HM077140

All affected vehicles have been identified by tbe 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:

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.

#### 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. The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required should be ordered through regular channels, as follows:

Description Part Number Quantity Per Vehicle ----------- ----------- -------------------- Hose - Fuel Feed 10101301 1 Engine End O-Ring Included

Hose - Fuel Return 10101315 1 Engine End O-Ring Included

Fuel Feed Pipe (O-Ring) 22514722 1 Chassis End

Fuel Return Pipe (O-Ring) 22516256 1 Chassis End

#### PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card, RAPID terminal or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 2A Replace Fuel Feed and Fuel 1 hour Return Hose/Pipe Assemblies

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. Place car on hoist. Open and prop hood. Install fender covers on both fenders.

2. CAUTION: To reduce the risk of fire and personal injury, it is necessary to relieve fuel system pressure before servicing fuel system components. To do this:

Remove "Fuel Pump" fuse (25 amp. at position #12) from fuse block in passenger compartment.

Crank engine. Engine will start and run until fuel supply remaining in fuel lines has been consumed. Engage starter for three (3) seconds to assure relief of any remaining pressure.

Unless this procedure is followed before servicing fuel lines or connections, fuel spray could occur.

3. Disconnect negative cable at battery.

4. At air cleaner, disconnect hoses and electrical connector to Manifold Absolute Pressure (MAP) sensor. Remove air cleaner and air inlet hose.

5. Disconnect electrical connectors at Manifold Air Temperature (MAT) sensor and at lower throttle body. Move the wiring harness back toward the cowl.

Do NOT remove the connector to the injector in the top of the throttle body.

6. Using a 19 mm extended socket, remove the MAT sensor and set aside for later reinstallation.

7. Loosen mounting bolts of power steering pump to provide clearance when the fuel lines are removed and replaced later. It is not necessary to remove the pump from the engine.

8. Unbolt clips (3) and (4) which retain the Fuel Feed and Fuel Return Hose/Pipe Assemblies to the top side of the engine (see illustration). Save the bolts and clamps for reuse.

9. Disconnect the Fuel Feed and Fuel Return Hose/Pipe Assembly fittings at the throttle body and at the chassis lines. Refer to illustration. Use a backup wrench while loosening fittings.

10. Hoist vehicle. Unbolt clip (6) from underside of intake manifold. Unscrew clip (14) from bracket which is bolted on the push rod cover. Save clips and bolts/screws for reuse.

11. Lower vehicle.

12. Remove botb the Fuel Feed and Fuel Return Hose/Pipe Assemblies, moving power steering pump as required for clearance.

13. Thread new Fuel Feed Hose/Pipe Assembly (Part Number 1010301) from area of power steering pump under the intake manifold and over the lift bracket (9) in illustration. Use new chassis end O-ring # 25514722.

At the lift bracket, the fuel hose must pass UNDER the spark plug wires, UNDER the wire to coolant temperature sensor, and UNDER the engine wiring harness (harness to starter and cooling fan).

In the area under the intake manifold, the fuel pipe must pass above all hoses and wires.

Move the power steering pump as necessary to permit connecting the fuel pipe to the throttle body fitting.

14. Repeat Step 14 with the new Fuel Return Hose/Pipe Assembly (Part Number 10101315). (Use Chassis end O-ring # 22516256).

15. Install the pipe fittings to the throttle body and the chassis pipes finger tight. Do not torque at this time.

16. Loosely install clip (4) and screw (5) at lift bracket (9) as shown in illustration.

Loosely install clip (3) and bolt (13) as shown in illustration.

17. Raise the vehicle and reinstall clip (6) as shown in illustration, torque bolt (7) to 27 N.m (20 lbs. ft.).

Reinstall clip (4) as shown in illustration, torque screw (15) securely.

18. Lower the vehicle and torque screw (5) to 10 N.m (90 lbs. in.). Torque bolt (13) securely.

19. Torque the pipe fittings at the throttle body to 27 N.m (20 lbs. ft.). Use a backup wrench.

20. Torque the hose fittings to the chassis fuel pipes at 27 N.m (20 lbs. ft.). Use a backup wrench and take care not to twist the hoses.

21. Inspect both hose/pipe assemblies to assure the following conditions:

- The MUST clear the shift lever on the transaxle by at least 10 mm (3/8 inch) in every gear position.

- They do not contact the transaxle Fluid Level Indicator.

- They do not contact the brake pipes..

The chassis fuel pipes should be vertical at the engine compartment rail.

22. Refer to the 1987 applicable Chassis Service Manual, Volume I, and torque power steering pump mounting bolts. Adjust belt tension per chart in Shop Manual as indicated.

23. Reinstall the MAT sensor.

24. Reinstall the electrical connectors at the MAT sensor and lower throttle body.

25. Reinstall air cleaner and air inlet hose. Reinstall electrical connector to MAP and hoses to air cleaner.

26. Reconnect negative cable battery.

27. Reinstall the "Fuel Pump" fuse.

28. Start the engine and check the fuel hose/pipe fittings at the chassis lines and the throttle body for leaks.

29. Turn off engine and install a campaign label.

30. Remove fender covers and close hood.

#### 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:

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

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in some 1987 Calais, Grand Am and Somerset Models equipped with 2.5L engines and five-speed manual transaxles. The fuel feed or fuel return hose at the engine may rub against a shift lever on the 5-speed transaxle. With time, a hole could be rubbed through the hose and fuel leak into the engine compartment. Under certain circumstances, this could result in an underhood fire.

To prevent the possibility of this condition occurring, the Fuel Feed and Fuel Return Hose/Pipe Assemblies at the engine will be replaced for you at no charge. Please contact your GM Dealer to arrange a service date. Instructions for this service have been sent to your Dealer. The labour time to perform the service is about one hour. Please ask your Dealer if you wish to know how much additional time will be necessary to process your vehicle.

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.

Further assistance, if required, may be obtained from the General Motors Zone Office nearest you. Your vehicle Owner's Manual provides the location and phone number of each respective Zone Office.

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

Service 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.