For 1990-2009 cars

# FUEL FEED AND RETURN HOSE PIPE ASSEMBLIES

CERTAIN 1987 CALAIS MODELS WITH 2.5L L68 MODELS/YEARS (VIN CODE U) ENGINE AND MT2 FIVE-SPEED MANUAL TRANSAXLE

#### CONDITION

General Motors has determined that a defect which relates to motor vehicle safety may exist in some 1987 Calais models equipped with 2.5L engines and 5-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.

VEHICLES INVOLVED

Certain 1987 Oldsmobile Calais models equipped with 2.5L L68 (VIN Code U) engines and MT2 5-Speed Manual Transaxies within the following vehicle breakpoints:

Plant Beginning Through and Including ----- --------- --------------------- Lansing North Start of Production HM307145

#### DEALER ACTION

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

Dealers are to perform this campaign on all involved vehicles 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 car 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.

Dealers are to contact owners of vehicles recently sold from your new vehicle inventory and arrange for the campaign correction to be performed.

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 No. 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 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 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 both the Fuel Feed and Return Hose/Pipe Assemblies, moving power steering pump as required for clearance.

13. Examine the fittings on the hose/pipe assemblies and the chassis pipes for missing or damaged 0-rings. If 0-rings need replacing, use part numbers indicated in the Parts information section.

14. Thread new Fuel Feed Hose/Pipe Assembly (part number 10101301) from area of power steering pump under the intake manifold and over the lift bracket, (9) in illustration:

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.

15. Repeat step 14 with the new Fuel Return Hose/Pipe Assembly (Part number 10101315).

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

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

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

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

Reinstall clip (14) as shown in illustration; torque screw (15) securely.

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

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

21. 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.

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

- They MUST clear the shift lever on the transaxle by at least 10 mm (3/8 inch) in everv 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.

23. Refer to the 1987 Oldsmobile (Calais) Chassis Service Manual, Volume 1, and torque the power steering pump mounting bolts as shown on page 3B3-6. Adjust belt tension per chart on page OA-17.

24. Reinstall the MAT sensor.

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

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

27. Reconnect negative cable at battery.

28. Reinstall the "Fuel Pump" fuse.

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

30. Turn off engine and install a campaign label.

31. Remove fender covers and close hood.

PARTS INFORMATION

To ensure parts are obtained as soon as possible, order them from GM Service Parts Operations (GMSPO) on a C.I.O. order, with NO special instruction code, but order on an Advise Code (2). Use the following part numbers:

Description Part Number Quantity Per Vehicle ----------- ----------- -------------------- Hose, Fuel Feed Front 10101301 1

Hose, Fuel Return Front 10101315 1

Seal, Fuel Feed Pipe (0-Ring) 22514722 Max. 2, as required

Seal, Fuel Return Pipe (0-Ring) 22516256 Max. 2, as required

WARRANTY CLAIM INFORMATION

PC PART-NO. TOT-PTS TC LAB-OP LHRS ST SUBLET

Replace Fuel Feed and Fuel Return Hose/Pipe Assemblies

96 V4500 1.0* .1 ---

*.l hour clerical adminstration may be added to the above operation.

Parts Allowance: Current dealer price, plus 30% handling allowance.

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.