CAMPAIGN: LACK OF ADEQUATE SERVICE OR MAINTENANCE. Pontiac Fiero 1986

For 1990-2009 cars

# CAMPAIGN: LACK OF ADEQUATE SERVICE OR MAINTENANCE

#### SUBJECT: LACK OF ADEQUATE SERVICE OR MAINTENANCE

#### Models: 1984-88 Pontiac Fiero Models with 2.5L L4 Engines (RPO LR8)

#### TO: ALL GENERAL MOTORS DEALERS

THIS CAMPAIGN BULLETIN SUPPLEMENTS CAMPAIGN BULLETIN 8A05B DATED MARCH 1989 AND SUPERCEDES CAMPAIGN BULLETIN 8R14 DATED FEBRUARY 1989. DISCARD BULLETIN 8R14.

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in 1984-88 Pontiac Fiero Model vehicles with 2.5L L4 engines (RPO LR8).

An interaction of the engine compartment environment in 1984-88 Pontiac Fieros and maintenance or service related factors results in the potential for engine compartment fires.

If combustible materials come in contact with the exhaust manifold, an engine compartment fire can result. Engine compartment fires can spread to the passenger compartment and cause injury to occupants.

To reduce the possibility of this condition occurring, all vehicles will have changes made in their underhood environment. Specifically, all vehicles will have a manifold barrier installed, a minor change to deck lid sealing, and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally, 1984-86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987-88 specifications.

#### VEHICLES INVOLVED:

Involved are certain 1984-88 Pontiac Fiero Model vehicles with 2.5L L4 engines (RPO LR8) produced within the following VIN breakpoints:

Model Year Plant From Through ----- ---- ------- -------- -------- P 1984 Pontiac EP200001 EP336842

P 1985 Pontiac FP200007 FP276371

P 1986 Pontiac GP200001 GP283974

P 1987 Pontiac HP200001 HP246581

P 1988 Pontiac JP200001 JP226402

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 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 to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ------------------- ---------------- 10184936 Service Kit (1984-85-86) 1 (Illustration A)

10184937 Service Kit (1987) 1 (Illustration B)

10184938 Service Kit (1988) 1 (Illustration C)

Breakdown of the specific parts included in these kits are shown on the applicable illustrations.

Additional parts necessary to correct engine compartment fluid leaks, or cooling system discrepancies, etc., are to be ordered through regular channels as required from the appropriate service parts catalogue.

#### NOTE: The campaign effectively supersedes previous campaigns 8A05 and 8R14 The following parts cannot be ordered from GMSPO and dealers should contact DGN if additional parts are needed.

8A05B Quantity/ Description Part Number Vehicle --------------------------- ----------- --------- "Check Engine Oil At Every Fill" Label NPN 1

"Engine Coolant System Fill Procedure" 10030499 1 Label

Revised 1984 Fiero Maintenance Schedule 10077793 1 Booklet

Supplement to 1984 Fiero Owner's Manual 10077794 1 Page 5-8

Supplement to 1984 Fiero Owner's Manual 10077795 1 Page 6-4

8R14

Quantity/ Description Part Number Vehicle ------------------ ----------- --------- Check Oil Reminder Label 10125898 1

Supplement to 1985 Owner's Manual 10122627 & 1 10122628

Supplement to 1986 Owner's Manual 10122629 1

Supplement to 1987 Owner's Manual 10122630 & 1 10122631

#### 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 Install Shield Kit 3.1 (1984)

3A Install Shield Kit 2.6 (1985) and (1986)

4A Install Shield Kit 2.5 (1987)

5A Install Shield Kit 2.4 (1988)

T8036 Owner Reimbursement on previous repairs

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.

IF THE INSPECTION PROCEDURE REVEALS ADDITIONAL OPERATIONS ARE NECESSARY, THE APPROPRIATE "T" LABOUR OPERATIONS SHOULD BE SELECTED FROM FOLLOWING CHARTS. THESE SHOULD ONLY BE USED IN CONJUNCTION WITH 2A, 3A, 4A, 5A.

COOLING SYSTEM

Labour Labour Description Hours Operation ---------------------- ------ -------- Clamp Rad. Hose - Replace .2 T3203 Add: To Replace Each Additional .1

Coolant Hoses - Replace Upper .6 T3204

Coolant Hoses - Replace Lower .6 T3205

Replace Both Upper and Lower 1.0 T3206

Coolant Pump Inlet Replace .7 T3207

Pump/Gasket Coolant Replace 2.0 T3209

Sensor Coolant Temp. .4 T3213

Coolant Fan Switch - Replace .3 T3215

Engine Coolant Temp. Switch - Replace .3 T3216

Thermostat Housing and/or Gasket .4 T3242

Heater Pipe Clamp - Replace .3 T3229

Hose, Htr. Pipe to Eng. Comp. Inlet - Replace .4 T3232

Hose, Eng. Comp. Inlet to Engine - Replace .4 T3233

Hose, Htr. Pipe to Engine Outlet - Replace .4 T3234

Blade/Motor Cooling Fan - Replace .6 T3235

Relay, Cooling Fan - Replace .3 T3236

Wiring and/or Connector - Repair .5 T3237

Gasket, Cylinder Head 3.3 T3218

EXHAUST SYSTEM

Shield Exhaust - Replace .3 T3244 Each Additional .2

Front Exhaust Pipe .7 T1625 (Manifold to Converter)

LUBRICATION SYSTEM

Rocker Gasket .5 T3172

Cap Oil Filler - Replace .2 T3220

Crankcase Ventilation Grommet .2 T3227

FUEL SYSTEM

Nut/Gasket Fuel Inlet or Outlet - Replace .3 T3211

Pipe Fuel Pump to Throttle Body Unit - Replace .3 T3212

Pipe Fuel Repair .6 T1626

TRANSMISSION OIL COOLER

Labour Labour Description Hours Operation ------------------------------ ----- ------- Upper Trans. Oil Cooler Hose - Replace .2 T3180

Lower Trans. Oil Cooler Hose - Replace .2 T3181

Both Trans. Oil Cooler Hose - Replace .3 T3182

IGNITION SYSTEM/ENGINE COMPARTMENT WIRING

Wiring - Routing/Clips .2 T1627

BOLT BREAKAGE

Broken Cylinder Head Bolt (1) .2 T1628

SERVICE LOANER/CAR RENTAL

Car Rental - Parts Delay T3256

#### NOTE: CAR RENTAL (up to $40.00 per day for a maximum of 2 days) IS TO COVER PARTS DELAYS. CLAIMS IN EXCESS OF 2 DAYS WILL REQUIRE BDC REVIEW AND AUTHORIZATION.

If no labour operation number is listed for the repair performed, use the closest appropriate operation found in this bulletin.

#### REIMBURSEMENTS

Claims for customer reimbursements on previously paid repairs related ONLY to Broken Head Bolts, Engine Compartment Cooling System Leaks and/or Engine Compartment Wiring Harness Repairs will be considered. Owners should present documentation which reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity performing the repair.

Review the owner's documentation, and process under Repair Code 6A (authorization is required).

#### SERVICE PROCEDURE:

#### NOTE: The "Check Oil" reminder label and/or glove box supplements for Campaign 8A05B and/or 8R14 should be taken care of at this time if they are still open and claim under Campaign 0A12.

To reduce the effects of fluid leaks which may lead to engine compartment fires, GM dealers will do the following at no charge:

1. INSTALL EXHAUST MANIFOLD SHIELD

a. Remove right side grille panel and disconnect negative battery cable.

b. Remove rear engine compartment lid (on 1984 models also remove centre grille from engine compartment lid). Remove rubber dust seal and retaining clips (rivets) from leading edge (front) of deck lid assembly (and leave off). On 1984 vehicles, remove plastic deflector from underside of deck lid grille opening (and leave off); reinstall centre grille. (See illustration D for component identification.)

c. Remove air cleaner assembly.

d. Remove dipstick tube.

e. Disconnect 02 sensor wire.

f. Raise vehicle.

g. Remove and discard converter splash shields (only on 1984 -85) .

h. Remove converter pipe to exhaust manifold bolts.

i. Remove A/C mount bracket bolt and install new stud-headed bolt (#3) in block above oil pan rail at A/C bracket. Spacer (1984-86: #4 - WITHOUT A/C or NO Spacer WITH A/C; 1987 & 88: #4 - WITHOUT A/C or #26 - WITH A/C) to be installed on stud.

j. Lower vehicle.

k. Remove exhaust manifold and gasket.

l. Clean gasket surface on cylinder head and exhaust manifold if a new manifold is not installed.

m. Install protective tape wrap (provided in kit) on engine wiring harness starting at thermostat housing and ending at bulkhead connect- or at bulkhead connector on 1984 vehicles Illustration E.

n. Install new cylinder head bolts (1984-86 vehicles only) provided in kits. New cylinder head bolts should be installed using torque values described in Illustration A & B. HEAD BOLTS SHOULD BE REPLACED ONE AT A TIME. If a broken head bolt is encountered, refer to Dealer Service Bulletin 89-625-111 for the proper procedure.

o. Install new 02 sensor (#21, 1984-86) in exhaust manifold.

p. Install deflector (#2), gasket (#23), and exhaust manifold (#7) manifold (#7) (new manifold provided for 84-86 vehicles). Shield is not gasketed against cylinder head. Note that shield leg/bracket has different spacers (#4 or #26) or no spacer depending upon model year and equipment.

q. Manifold bolts should be installed using torque values described in Illustration A, B & C. Lock tabs (#6, 1984-88) should be installed on outboard manifold runner bolts.

r. Install dipstick tube.

s. Install new exhaust pipe seal. Loosely install one (1) converter pipe to exhaust manifold bolt (#12).

t. Raise vehicle.

u. Install remaining manifold to converter pipe bolt (#12) and tighten using torque values described in Illustration A & B.

v. Install shield leg nut (#5) and washer (#19) and tighten using torque values described in Illustration A, B & C.

w. Lower vehicle.

x. Remove starter motor heat shield and clamps (may already be removed) from exhaust manifold to converter exhaust pipe.

y. Install new heat stove (#20 & 25, 1984-86 only) as shown in Illustration A with band clamps (#20) on front pipes.

z. Install air cleaner assembly.

aa. Connect negative battery cable and install right side grille panel.

#### NOTE: THE REMAINING STEPS BELOW ARE INSPECTION ITEMS. IT IS IMPERATIVE THAT CARE BE EXERCISED IN INSPECTION. THE PARTICULAR ITEMS HAVE BEEN CHOSEN DUE TO THEIR POTENTIAL ASSOCIATION WITH UNDERHOOD FIRE. SEE THE NOTES ON EACH STEP FOR THE TYPES OF REPAIRS AUTHORIZED.

PLEASE NOTIFY YOUR CUSTOMER OF ANY ISSUES NOT FIXED IN YOUR INSPECTION WHICH WILL BE HIS/HER RESPONSIBILITY.

ANY ISSUES NOT SPECIFICALLY AUTHORIZED IN THIS BULLETIN MAY BE DISCUSSED WITH YOUR APPROPRIATE BDC CONTACT PERSON WITH SERVICE RESPONSIBILITY.

2. INSPECT COOLING SYSTEM

a. Visual check of coolant level. Adding needed coolant to specified level and/or diagnostic procedure will be authorized if coolant loss is determined to be a chronic problem. NOTE: With engine cold, perform a pressurized leak

#### NOTE: With engine cold, perform a pressurized leak test as described in 1986 Fiero Service Manual, Section 6B-14, 15.

b. Visually inspect for significant leaks. Repairs are authorized for external coolant leaks from any engine compartment area, specifically thermostat housing, water pump, coolant hoses and connectors in engine compartment.

c. Visually inspect for signs of coolant hose wear or aging. Replacement of of damaged hoses is authorized.

d. Perform a function check of cooling fan. Replacement of relay, coolant switch, wiring or fan is authorized to make functional.

3. INSPECT EXHAUST SYSTEM

a. Observe for any significant leaks (vehicle running). Repairs are auth- orized for any leaks forward of the catalytic converter. Also repairs should be made if any irregularity in manifold or front pipe prevents proper installation of the new shield.

b. Visually inspect for presence of appropriate heat shields. Repair or replacement will be authorized for starter shield, converter shield, muffler shield, or bulkhead shields. See Illustration F and G for correct configurations.

4. INSPECT LUBRICATION SYSTEM

a. Visually inspect for indications of significant oil leakage. Repairs seepage will not be authorized, only areas with significant leakage. Specifically, rocker cover gasket repair or PCV breather are authorized. Oil pan or filter leaks are not normally covered.

b. Visually verify update to 4 litres system. Vehicles should all be equipped with the larger oil filter (PF51 style). Replacement of the filter is authorized if vehicle was not previously retrofit.

c. Check oil level. Make up oil authorized for vehicles 1 litre or more low.

5. INSPECT FUEL SYSTEM

a. Visually inspect for signs of leakage inside engine campartment. Repairs are authorized for retorque, new fitting, or hose replacement.

b. Visually inspect evaporative emission system for integrity of harness connections. Reinstallation of harness authorized if necessary. Tampered systems to be replaced only if vapour lines were left open (presenting some fire risk). All emission discrepancies should be noted in writing to the owner and noted on the repair order.

6. INSPECT TRANSMISSION OIL COOLER

a. Visually inspect for signs of oil cooler hose leakage near transmission. Repairs are authorized for hose degradation or fitting tighten/replace.

7. INSPECT IGNITION SYSTEM

a. Visually inspect for proper spark plug wire routing. Rerouting authorized if required and replacement of spark plug wire retainer clips only.

8. INSPECT ENGINE COMPARTMENT WIRING

a. Visually inspect for correct routing of engine wiring harness in vicinity of exhaust manifold. Reroute and clip as necessary.

b. Visually inspect for correct battery cable routing. Reroute and clip if required.

c. Visually inspect for any obvious chafing/wear on starting/charging circuit wiring. Wire, conduit or retainer replacement authorized if necessary.

9. VISUALLY INSPECT FOR ANY COMBUSTIBLE MATERIALS HANGING LOOSE IN FRONT OF ENGINE COMPARTMENT. (e.g. conduit, insulation) Remove as required.

10. Install rear engine compartment lid and left side grille panel.

NOTE THAT COMPONENTS ON THE BULKHEAD WILL NOW BE BARELY VISIBLE FROM OUTSIDE THE VEHICLE WITH THE ENGINE COMPARTMENT LID CLOSED. THIS CHANGE INCREASES AIR FLOW THROUGH THE ENGINE COMPARTMENT. SHOULD YOUR CUSTOMER WISH, THE VISIBLE BULKHEAD COMPONENTS MAY BE SPRAYED FLAT BLACK.

#### 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:

General Motors of Canada has determined that a defect which relates to motor vehicle safety exists in 1984-88 Pontiac Fiero Model vehicles with 2.5L 4 cylinder engines.

An interaction of the engine compartment environment in 1984-88 Pontiac Fieros and maintenance or service related factors results in the potential for engine compartment fires.

If combustible materials come in contact with the exhaust manifold, an engine compartment fire can result. Engine compartment fires can spread to the passenger compartment and cause injury to occupants.

To reduce the possibility of this condition occurring, all vehicles will have changes made in their underhood environment. Specifically, all vehicles will have a manifold barrier installed, a minor change to decklid sealing, and a general inspection (and repair as necessary) of underhood fluid and wiring systems. Additionally, 1984-86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987-88 specifications.

This service will be performed 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.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777, or if you live in Quebec, 1-800-263-7854.

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 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.