For 1990-2009 cars

# CAMPAIGN:FUEL FILTER NECK TANK SOLDIER JOINT

#### SUBJECT: FUEL FILLER NECK TO FUEL TANK SOLDER JOINT

#### Models: 1991-92 Chevrolet Camaro and Pontiac Firebird

#### TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1991-92 Chevrolet Camaro and Pontiac Firebird model vehicles fail to conform to the requirements of Canada Motor Vehicle Safety Standard (CMVSS) 301, "Fuel System Integrity." These vehicles could exhibit cracks or "pin holes" at the fuel filter neck solder joint. This could result in fuel odor or fuel leakage. If an ignition source was present, fuel leakage resulting from this condition could result in a vehicle fire.

To prevent this condition from occurring, dealers are to inspect the fuel tanks of involved vehicles and replace those tanks that exhibit the crack or "pin hole" condition. In addition, for vehicles which require fuel tank replacement, owners are being informed that a "loaner" car will be provided free of charge until the fuel tank replacement is completed.

#### VEHICLES INVOLVED:

Involved are certain 1991-92 Chevrolet Camaro and Pontiac Firebird model vehicles built within the following VIN breakpoints:

#### CHEV

#### Year Model Plant Plant Code From Through

1991 F-Car Van Nuys L ML100001 ML200843 1992 F-Car Van Nuys L NL100001 NL170008

#### PONTIAC

#### Year Model Plant Plant Code From Through

1991 F-Car Van Nuys L ML200001 ML250250 1992 F-Car Van Nuys L NL200001 NL227568

#### NOTE: PLEASE CHECK DCS SCREEN 45 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 kilometers traveled, 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:

It is anticipated that less than 3% of suspect fuel tanks assemblies will require replacement. Place orders accordingly.

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

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 10269091 Fuel Tank Unleaded 1 - If Required 22515965 Sending Unit Seal 1 - If Required 10113029 Fuel Tank Insulator - Upper 2 - If Required

#### LIQUID LEAK DETECTOR

Each dealer will be shipped a bottle of SNOOP Liquid leak detector, J-41365, for use in this campaign during the week of May 23, 1994. This first bottle of liquid leak detector is being furnished at no charge. Additional bottles, if required, may be purchased by contacting Kent-Moore Tool Company at 1-800-345-2233. Liquid leak detector may also be purchased locally if the dealer prefers but ONLY "SNOOP" brand liquid leak detector is to be used in the performance of this campaign.

Each bottle contains enough liquid leak detector to inspect approximately 16 vehicles (8 oz. bottle - approx. 1/2 oz: per vehicle).

#### 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 Inspect Fuel Tank Filler Neck For Leaks .4 - Not Necessary To Drain Fuel From Tank - No Leaks Present, No Repair Required 2A Inspect Fuel Tank Filler Neck For Leaks .5 - Necessary To Drain Fuel From Tank - No Leaks Present, No Repair Required 3A Inspect Fuel Tank Filler Neck For Leaks 2.3 - Not Necessary To Drain Fuel From Tank - Leaks Found, Fuel Tank Replaced 4A Inspect Fuel Tank Filler Neck For Leaks 2.4 - Necessary To Drain Fuel From Tank - Leaks Found, Fuel Tank Replaced 7A Fuel Tank Replaced, Customer "Loaner" - Car Provided

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.

#### SERVICE PROCEDURE:

#### TOOLS REQUIRED

J-41365 SNOOP Liquid Leak Detector J-24460-01 Radiator Pressure Test Pump

#### NOTICE: GASOLINE OR GASOLINE VAPOURS ARE HIGHLY FLAMMABLE. IF AN IGNITION SOURCE IS PRESENT A FIRE COULD OCCUR. HAVE A DRY CHEMICAL (CLASS B) FIRE EXTINGUISHER NEARBY.

#### INSPECTION PROCEDURE:

1. With ignition key in the run position, check fuel gauge to insure them is no more than 3/4 of a tank of fuel in vehicle.

#### NOTICE: In cases where gauge indicates above 3/4 of a tank of fuel, remove enough fuel from tank so that a 3/4 gauge reading is indicated. Follow applicable "Draining Fuel Tank" procedure in applicable service manual Section 6C-6, Engine Fuel.

2. Disconnect negative battery cable after noting radio settings so they maybe reset later.

3. Remove fuel tank filler cap.

4. Remove fuel filler door and cup assembly. Install filler cap and rotate until at least three clicks are noted.

5. Remove left rear wheel well fuel filler neck shield (2 attaching screws).

6. Underhood, in area of fuel vapor canister, locate tank pressure control valve and disconnect valve from hose which connects valve to chassis fore-aft vapor pipe (Figure 1).

7. Disconnect radiator test cap from Radiator Pressure Test Pump (Kent-Moore Tool J-24460-01 or equivalent) at hose to cap fitting.

#### NOTICE: Do not, under any circumstances, use shop air in place of radiator pressure tester hand pump. Over pressurizing of fuel tank or emissions system could lead to system leakage or damage. If an ignition source is present, a fire could occur.

8. Insert threaded end of radiator pressure tester. hose fitting into hose connected to chassis fore-aft vapor pipe.

9. At a rate of two (2) strokes per second, pressurize fuel system with applicable number of full strokes of Radiator Pressure Tester Hand Pump as indicated below by fuel gauge reading:

FUEL GAUGE READING NUMBER OF STROKES ------------------ ----------------- Empty to 1/4 50 1/4 to 1/2 45 1/2 to 3/4 35

10. Immediately proceed to rear of vehicle at fuel filler door opening. Working through wheel well access opening and observing through the quarter panel fuel filler door opening, apply a liberal amount of SNOOP Liquid Leak Detector (Kent-Moore J-41365) completely around fuel tank to filler neck solder joint following instructions on container (Figure 2).

#### NOTICE: A flashlight or other light source should be used to illuminate area being inspected.

11. Visually inspect entire area around solder joint and based on whether or not bubbles appear in SNOOP Liquid Leak Detector, proceed as indicated below:

A. Bubbles Apparent Around Joint - Leak indicated, procced directly to "Fuel Tank Replacement Procedure."

B. No Bubbles Apparent Around Joint - Slowly loosen fuel filler cap while listening for pressure being released past the fuel filler cap seal. If pressure release is heard, proceed with remainder of "Inspection Procedure" steps (steps 12 through 17).

#### NOTICE: If pressure release is not heard repeat Steps 9-11 insuring there are no leaks at hose connections and filler cap. Correct leaks as required and proceed with inspection procedure.

12. Disconnect Radiator Pressure Test Pump from chassis fore-aft vapor pipe hose and connect tank pressure control valve to hose. Secure hose with existing clamp.

13. Install fuel filler neck shield (2 attaching screws).

14. Install fuel filler door and cup assembly (6 attaching screws).

15. Reconnect negative battery cable. Reset radio settings and clock.

16. If fuel was drained from tank in step 1, refill tank to previous level with fuel that was drained.

17. Install Campaign Identification Label.

#### FUEL TANK REPLACEMENT PROCEDURE

1. Disconnect Radiator Pressure Test Pump from chassis fore-aft vapor pipe hose and connect tank pressure control valve to hose. Secure hose with existing clamp.

2. Replace existing fuel tank and fuel sender assembly 0-ring gasket with new components following applicable service manual procedures, Section 6C-6, Engine Fuel.

3. Install fuel filler door and cup assembly (6 attaching screws).

4. Reconnect negative battery cable. Reset radio settings and clock.

5. If fuel was drained from tank in step 1 of inspection procedure, refill tank to previous level with fuel that was drained.

6. 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.

Dear General Motors Customer.

General Motors of Canada Limited has determined that certain 1991-92 Chevrolet Camaro and Pontiac Firebird model vehicles fail to conform to the requirements of Canada Motor Vehicle Safety Standard (CMVSS) 301, "Fuel System Integrity." These vehicles could exhibit cracks or "pin holes" at the fuel filler neck solder joint. This could result in fuel odor or fuel leakage. If an ignition source was present, fuel leakage resulting from this condition could result in a vehicle fire.

To correct this condition, your dealer will inspect your vehicle's fuel tank and replace the tank if it exhibits the crack or "pin hole" condition.

This service will be provided for you at no charge.

In addition, if your vehicles fuel tank requires replacement, you will be provided a "loaner" car (or alternate means of transportation) fire of charge until the replacement is complete.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your 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 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.