CAMPAIGN: FUEL LEVEL SENDER ARM/TANK INTERFERENCE. GMC Truck S15 Pickup - 4WD 1992

For 1990-2009 cars

# CAMPAIGN: FUEL LEVEL SENDER ARM/TANK INTERFERENCE

#### SUBJECT: FUEL LEVER SENDER ARM/TANK INTERFERENCE

#### MODELS: 1992 S/T Pickups Equipped with 20 Gallon Fuel Tanks (RPO NQE) (Syclone Models Not Involved)

#### TO: ALL AFFECTED DEALERS:

DCS MESSAGE REGARDING STOP DELIVERY ON INVOLVED V.I.N.'S WAS SENT TO YOU AUGUST 22, 1991

General Motors of Canada has determined that certain 1992 S/T Pickups equipped with 20 gallon fuel tanks (RPO NQE) my experience fuel gauge inaccuracies due to the fuel meter float hanging up against the side wall of the fuel tank reservoir. When this occurs, the fuel gauge will continue reading approximately 1/2 full regardless of how much fuel remining in the tank.

This condition may be corrected by replacing the fuel meter with kit #25027768.

#### VEHICLES INVOLVED:

Dealer codes and vehicles involved are listed below:

V.I.N. DEALER V. I. N. DEALER ------ ------ -------- ------ 1GCCS14Z7N2100064 95555 1GCCT19Z8N2100077 95391

1GTCS14Z8N2500019 87082 1GTCT14ZXN2500021 87035

1GCCT19ZXN2100145 95074 1GCCS14Z7N2100176 87081

1GTCS14A8N2500029 87004 1GCCS14ZIN2100187 85784

1GCCS19Z4N2100189 82104 1GCCS14Z5N2100208 96196

1GCCS14Z4N2100233 88115 1GCCT19Z5N2100280 86666

1GCCS14Z6N2100301 87081 1GCCS14Z8N2100302 96196

1GCCT19ZON2100347 81094 1GCCS14Z8N2100350 82103

1GCCS14Z4N2100359 95472 1GCDT19ZIN2100362 88749

1GCCS14Z2N2100375 84270 1GCCS14Z2N2100411 96269

1GCCT19Z7N2100426 81134 1GCCS19ZON2100447 95527

1GCCS14AXN2100487 96215 1GTCS14Z4N2500101 87087

1GCCS14Z4N2100510 95074 1GCCS14Z6N2100511 87093

1GTCS14Z4N2500115 84029 1GCCrl4Z4N2100567 88909

1GCCS14Z4N2100703 87081 1GCCS14ZlN2100707 87064

1GTCS14Z5N2500141 84266 1GCCS19Z4N2100743 88513

1GCCS14Z2N2100747 96208 1GCCS14Z3N2100787 86890

1GCCT19ZON2100798 88613 1GCCT19Z7N2100846 87122

1GCCT19Z5N2100876 84270 1GCCS14ZON2100892 95299

1GCCS19ZON2100898 96137 1GCCS14A9N2100903 87002

1GCCT19ZIN2100941 81134 1GCCT19Z4N2100951 84275

1GCCT14ZON2100968 87081 1GCCS19Z2N2100983 95299

1GCCS14Z2N2101008 87136 1GCCS14Z3N2101034 85969

1GCCS19Z6N2101036 84277 1GCCS19Z9N2101175 84209

1GCCT14Z6N2101204 87081 1GCCS14Z4N2101222 86763

1GCCS14Z5N2101245 95336 1GCCrl9Z5N2101459 96136

1GCDT14Z3N2101536 81052 1GTCT14Z9N2500320 87099

1GCCS19Z2NO100736 87097 1GCCS19Z9NO100832 84783

1GCCS19Z7NO101056 88310 1GCCS19Z3NO101118 81098

1GCCS19Z7NO101171 86864 1GCCS19Z7NO100232 84686

1GCCT19Z9NO100410 86558 1GCCS19ZXNOIOO421 86534

1GCCS19ZlNOlOO565 86584

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:

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 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 front 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 are to be obtained from General Motors Service Parts Operations (GMSPO).

Part Number Description Quantity/Vehicle ----------- ----------- --------------- 25027768 Fuel Meter Kit 1

#### 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 ----------- ------------ -------------- 2A R&R Fuel (In Tank) Pump 1.9

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 handing.

#### SERVICE PROCEDURE:

To replace fuel meter the following procedure may be used:

1. Relieve fuel pressure from system following the proper procedure.

2. Remove negative battery cable.

3. Drain fuel from fuel tank.

- Have a dry chemical (Class B) fire extinguisher nearby.

#### CAUTION:

NEVER DRAIN OR STORE GASOLINE OR DIESEL FUEL IN AN OPEN CONTAINER, DUE TO THE POSSIBILITY OF FIRE OR EXPLOSION.

4. Use a hand operated pump device to drain as much fuel as possible through the filler neck. On some fuel tank installations, the filler neck is too long to gain access to the fuel. If the tank is not full, disconnect filler neck nose, at the fuel tank, to gain access to the fuel.

#### Alternate Method:

a. Disconnect fuel feed pipe and attach a hand operated pump device.

b. Energize the fuel pump relay.

c. With fuel pump running, operate hand pump to remove fuel.

5. Raise vehicle on hoist

6. Disconnect propeller shaft, move out of the way and secure.

7. Remove clamps from filler neck hose and vent line. Figure 4-45 in X-9129 S/T Truck Service Manual, Page 4-3 1.

8. Remove fuel tank retaining straps. Figure 4-47 in X-9129 S/T Truck Service Manual, Page 4-31.

- Support the fuel tank.

9. Remove sender unit wires, hoses, and ground strap.

- Lower the fuel tank to gain access.

10. Remove fuel tank from the vehicle.

11. Remove sender unit and pump by turning the cam lock counter-clockwise using tool J-36608 or J-24187. Figure 4-34 in X-9129 S/T Truck Service Manual, Page 4-3 1.

12. Disconnect electrical terminals from pump.

13. Remove clamps from rubber coupler.

#### NOTE: MARK POSITION OF STRAINER ON PUMP; remove strainer by rotating in one direction while pulling off and discard.

14. Pull the fuel pump up into the attaching hose while pulling outward from the bottom support.

- Do not damage rubber isolator.

15. Install fuel pump assembly into the attaching hose.

#### NOTE: The fuel pump cannot be run dry because bearing damage can result in as little as 15 seconds. Also, care must be taken not to fold over or twist the strainer, when installing the sending unit as this will restrict fuel flow.

- Use the new strainer and align to original position.

16. Seat rubber isolator and pump securely in mounting bracket.

- Tighten both clamps securely.

17. Install sending unit and fuel pump assembly into the fuel tank

- Use the new 0-ring seal

18. Reinstall fuel tank as per specifications in Figure 4-47 in X-9129 S/T Truck Service Manual, Page 4-31, and reconnect hoses and electrical connectors.

19. Connect propshaft, torque to 29 N.m (15 lbs. ft.).

20. Lower vehicle.

21. Connect negative battery cable.

22. Check old fuel for contamination before refilling fuel tank.

23. Start vehicle and inspect all connections for leaks.

24. Install "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.

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.