For 1990-2009 cars

# CAMPAIGN: UPPER INTAKE MANIFOLD FRACTURE

#### PRODUCT SAFETY CAMPAIGN

#### SUBJECT: 97-C-02 - UPPER INTAKE MANIFOLD FRACTURE ----------------------------------------

#### MODELS: CERTAIN 1996 PONTIAC BONNEVILLE; OLDSMOBILE NINETY EIGHT, EIGHTY EIGHT; BUICK PARK AVENUE, LESABRE, RIVIERA, REGAL; (C,H,G,W MODELS) AND 1997 BUICK LESABRE (H MODEL) EQUIPPED WITH 3.8L ENGINE (RPO L36, VIN K) --------------------------------------------------------------------

The Highway Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty (60) days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time.

If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation.

To avoid having to provide these burdensome solutions, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the divisional letter that is being sent to customers, the customers are being instructed to contact the appropriate Customer Assistance Center if their dealer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, they are instructed on how to contact the National Highway Traffic Safety Administration.

#### DEFECT INVOLVED

General Motors 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:

PLANT YEAR DIVISION MODEL PLANT CODE FROM THROUGH

1996 PONTIAC Bonneville Orion "4" SOP T4242479 1996 PONTIAC Bonneville Buick City "H" SOP TH215935 1996 OLDS Ninety Orion "4" SOP T4312677 Eight 1996 OLDS Eighty Orion "4" SOP T4847606 Eight 1996 BUICK Park Ave. Buick City "H" SOP TH638915 1996 BUICK LeSabre Buick City "H" SOP TH454186 1996 BUICK Riviera Orion "4" SOP T4714125 1996 BUICK Regal Oshawa II "1" SOP T1473360 1997 BUICK LeSabre Buick City "H" SOP VH444313

#### NOTICE: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states.

Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

#### 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.

Model Axle Calibrate. CD CD ROM Year. Carline Ratio Emissions No. ROM Release No. Date

96 C (O,B) 2.84 Nationwide 16234094 9 5/2/96 96 C (0,B) 2.84 Unleaded 16238434 9 5/2/96 Export 96 C (B) 3.06 Nationwide 16234104 9 5/2/96 96 C (B) 3.06 Unleaded 16238444 9 5/2/96 Export (Europe) 96 C (B) 3.06 Unleaded 16238454 9 5/2/96 Export 96 G (B) 3.05 Nationwide 16234114 8 4/1/96 96 G (B) 3.05 Unleaded 16238464 8 4/1/96 Export 96 H(P,O,B) 2.84 Nationwide 16241234 9 5/2/96 96 H(P,O,B) 2.84 Unleaded 16238474 9 5/2/96 Export 96 H(P,B) 3.06 Leaded 16238484 9 5/2/96 Export 96 H(B) 3.06 Nationwide 16234144 11 5/31/96 96 H(B) 3.06 Unleaded 16238494 11 5/31/96 Export 96 H (P,O) 3.06 Nationwide 16234154 9 5/2/96 96 H (P,O) 3.06 Unleaded 16238504 9 5/2/96 Export 96 W (B) 3.06 Nationwide 16240644 9 5/2/96 96 W (B) 3.06 Unleaded 16240654 9 5/2/96 Export 97 H (B) 2.84 Nationwide 16242734 10 5/6/96 97 H (B) 2.84 Unleaded 16242744 10 5/6/96 Export 97 H (B) 3.06 Nationwide 16242754 10 5/6/96 97 H (B) 3.06 Unleaded 16242764 10 5/6/96 Export

#### CUSTOMER NOTIFICATION

Customers will be notified of this campaign on their vehicle by General Motors (see copy of divisional customer letter included with this bulletin).

#### DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the appropriate divisional customer letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your 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.

#### SERVICE PROCEDURE

#### IMPORTANT: A 1996 Techline CD ROM titled Disc 11 (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 Center help line. 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 #11 CD ROM or later software matching the vehicle. Refer to up-to-date Techline equipment users instructions.

3. Install GM Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in by the customer for periodic servicing. When installing the new Campaign Identification Label, be sure to install the clear protective covering. Additional Campaign Identification Labels can be obtained from VISPAC Incorporated by calling 1-800-269-5100 (Monday-Friday, 8:00 a.m. to 4:30 p.m. EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

REPAIR PART FAILED PARTS LABOR LABOR PERFORMED COUNT PART NO. ALLOW CC-FC 0P HOURS

PROM- 0 N/A N/A MA-96 V9943 0.4 Reprogramming Flash E PROM

*For Campaign Administrative Allowance, add 0.1 hours to the "Labor Hours".

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission

July 1996

Dear Oldsmobile Customer:

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

REASON FOR THIS SAFETY RECALL: General Motors has decided that a defect which relates to motor vehicle safety exists in the vehicle engine control system of certain 1996 Oldsmobile Ninety Eight and Eighty Eight model vehicles equipped with a 3.8L V6 engine (RPO L36). 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 occurred, it could result in personal injury.

WHAT WE WILL DO: To prevent this condition from occurring, your Oldsmobile retailer will update the vehicle Powertrain Control Module with new programming software. Of course, this service will be performed at no cost to you.

WHAT YOU SHOULD DO: Please contact your Oldsmobile retailer immediately to arrange a service date. Instructions have been sent to your retailer. Please ask your retailer if you wish an estimate of the total time needed to schedule, process and return your vehicle. Included in this time would be about thirty (30) minutes for a technician to perform the work required. You may have your vehicle serviced at the authorized Oldsmobile retailer of your choice.

Your Oldsmobile retailer is best equipped to obtain parts and provide service to promptly correct your vehicle. However, if you take your vehicle to your retailer on the agreed service date, and they do not remedy this condition then or within five days, we suggest you call Oldsmobile Customer Assistance (1-800-442-6537). Deaf, hearing impaired, or speech impaired persons with telecommunications devices for the deaf (TDD/TTY) may contact Oldsmobile Customer Assistance at 1-800-TDD-OLDS (1-800-833-6537). They will assist you and the retailer in getting your vehicle corrected.

After contacting your retailer and Oldsmobile Customer Assistance, if you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may write the Administrator, National Highway Traffic Safety Administration, 400 Seventh St., S.W., Washington, D.C. 20590 or call 1-800-424-9393 (Washington, D.C. residents call 366-0123).

PRECAUTIONS TO TAKE WHEN STARTING YOUR VEHICLE UNTIL CORRECTIONS ARE MADE: Although the likelihood of this condition occurring is very low, we suggest that the vehicle hood be shut whenever starting your vehicle. If possible, start your vehicle only in an open area.

COURTESY TRANSPORTATION: Should a delay in repairing your vehicle occur, to minimize your inconvenience, Oldsmobile retailers may offer various courtesy transportation options.

OWNER REPLY CARD: The enclosed owner reply card identifies your vehicle. Presentation of this card to your retailer will assist in making the necessary correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action for your safety and continued satisfaction with our products.

OLDSMOBILE DIVISION General Motors Corporation

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.