For 1990-2009 cars

# CAMPAIGN: UPPER INTAKE MANIFOLD FRACTURE

#### SUBJECT: UPPER INTAKE MANIFOLD FRACTURE ------------------------------

#### Models: 1996 Pontiac Bonneville; Oldsmobile Ninety Eight, Eighty Eight; Buick Park Avenue, LeSabre, Riviera, Regal; and 1997 Buick LeSabre Equipped with 3.8L Engine (RPO L36, VIN K) ----------------------------------------------------------------

#### TO: ALL GENERAL MOTORS DEALERS

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General Motors of Canada Limited has decided that a defect which relates to motor vehicle safety exists in certain 1996 Pontiac Bonneville; Oldsmobile Ninety Eight and Eighty Eight; Buick Park Avenue, LeSabre, Riviera, Regal; and 1997 Buick LeSabre model vehicles equipped with a 3.8L V6 engine (RPO L36, VIN K). These vehicles may exhibit, under a certain set of complex conditions, a backfire during engine starting that can cause breakage of the upper intake manifold. This can cause a no-start condition and possibly an engine compartment fire Also, if a person was in the immediate vicinity of the intake manifold when the hood was open, and this backfire condition occurred, it could result in personal injury.

To correct this condition, dealers are to reflash the vehicle PCM with new programming software. Until the campaign repair is made, it is suggested that the vehicle hood be shut whenever starting the vehicle to reduce the chance of personal injury.

#### VEHICLES INVOLVED:

Involved are certain 1996 Pontiac Bonneville; Oldsmobile Ninety Eight and Eighty Eight; Buick Park Avenue, LeSabre, Riviera and Regal and 1997 Buick LeSabre model vehicles equipped with a 3.8L engine (RPO L36, VIN K) and built within the following VIN breakpoints:

Year Model Plant Plant Code From Through ---- ----- ----- ---------- ---- -------

1996 Pontiac Bonneville Orion 4 SOP T4242479 1996 Pontiac Bonneville Buick City H SOP TH215935 1996 Oldsmobile Ninety Eight Orion 4 SOP T4312677 1996 Oldsmobile Eighty Eight Orion 4 SOP T4847606 1996 Buick Park Avenue Buick City H SOP TH638915 1996 Buick LeSabre Buick City H SOP TH454186 1996 Buick Riviera Orion 4 SOP T4714125 1996 Buick Regal Oshawa 2 1 SOP T1473360 1997 Buick LeSabre Buick City H SOP VH444313

#### NOTE: PLEASE CHECK DCS SCREEN 445 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.

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 travelled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

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:

A new flash program has been released to address the conditions mentioned above. The cumulative calibrations for all carlines and years affected by this campaign will be included and available from Service Technology Group on the #11 Techline CD ROM release on May 31, 1996. The following tracking table shows the individual carline calibration update number and initial CD ROM number.

Do not attempt to order the calibration number from GMSPO. They are programmed into the vehicles PCM via a Techline Tool Device.

CD ROM Model Axle Calibrate CD ROM Release Year Carline Ratio Emissions No. No. Date ----- ------- ----- ---------- --------- ------ ------- 1996 C (O,B) 2.84 U.S. 16234094 9 05/02/96 1996 C (B) 2.84 Canada & Overseas 16238434 9 05/02/96 1996 C (O,B) 3.06 U.S. 16234104 9 05/02/96 1996 C (B) 3.06 Europe Only 16238444 9 05/02/96 1996 C (B) 3.06 Canada & Overseas 16238454 9 05/02/96 1996 G (B) 3.05 U.S. 16234114 8 04/01/96 1996 G (B) 3.05 Canada & Overseas 16238464 8 04/01/96 1996 H (P,O,B) 2.84 U.S. 16241234 9 05/02/96 1996 H (P,O,B) 2.84 Canada & Overseas 16238474 9 05/02/96 1996 H (P,B) 3.06 Leaded Overseas 16238484 9 05/02/96 1996 H (B) 3.06 U.S. 16234144 11 05/31/96 1996 H (B) 3.06 Canada & Overseas 16238494 11 05/31/96 1996 H (P,O) 3.06 U.S. 16234154 9 05/02/96 1996 H (P,O) 3.06 Canada & Overseas 16238504 9 05/02/96 1996 W (B) 3.06 U.S. 16240644 9 05/02/96 1996 W (B) 3.06 Canada & Overseas 16240654 9 05/02/96 1997 H (B) 2.84 U.S. 16242734 10 05/06/96 1997 H (B) 2.84 Canada & Overseas 16242744 l0 05/06/96 1997 H (B) 3.06 U.S. 16242754 10 05/06/96 1997 H (B) 3.06 Canada & Overseas 16242764 10 05/06/96

#### 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 PROM - Reprogramming Flash E Prom 0.5

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus appropriate model year parts handling allowance.

#### SERVICE PROCEDURE:

#### IMPORTANT: A 1996 Techline CD ROM titled Disc 1 1 (May 31, 1996) or later software will be required to properly program all vehicles. Refer to Service Information Bulletin 53-65-08 filed in Section 6E for information on programming and the Techline Customer Support Centre help line, English 1-800-828-6860 and French 1-800-503-3222. As indicated in that bulletin, a Tech 2 will be required to program the 1997 LeSabres.

1. Prep vehicle for Powertrain Control Module reprogramming.

2. Flash PCM EE PROM using the #1 I CD ROM or later software matching the vehicle. Refer to up-to-date Techline equipment users instructions.

3. 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.

July 1996

Dear General Motors Customer:

General Motors of Canada Limited has decided that a defect which relates to motor vehicle safety exists in certain 1996 Pontiac Bonneville; Oldsmobile Ninety Eight and Eighty Eight; Buick Park Avenue, LeSabre, Riviera, Regal; and 1997 Buick LeSabre model vehicles equipped with a 3.8L V6 engine. These vehicles may exhibit, under a certain set of complex conditions, a backfire during engine starting that can cause breakage of the upper intake manifold. This can cause a no-start condition and possibly an engine compartment fire. Also, if a person was in the immediate vicinity of the intake manifold when the hood was open, and this backfire condition occurred, it could result in personal injury.

To prevent this condition from occurring, your dealer will update the vehicle Powertrain Control Module with new programming software.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a 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 Limit

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.