CAMPAIGN:PRODUCT IMPROVEMENT PHOENIX UNDERBODY REVISIONS. Pontiac Phoenix 1980

For 1990-2009 cars

# CAMPAIGN:PRODUCT IMPROVEMENT PHOENIX UNDERBODY REVISIONS

GENERAL MOTORS HAS DETERMINED THAT SOME 1980 PHOENIX MODELS MAY HAVE INADEQUATE HIGH MILEAGE FLOOR PAN DURABILITY AT THE ENGINE CRADLE MOUNT CUSHION AREA. TO PREVENT POSSIBLE FLOOR PAN CRACKING, IT WILL BE NECESSARY TO INSTALL A REINFORCEMENT PLATE BETWEEN THE ENGINE CRADLE MOUNT AND THE FLOOR PAN CROSS BODY BAR. IN ADDITION, THE AREA OF THE FRONT SHIPPING TIE DOWN SLOTTED HOLES MAY HAVE SUFFERED DAMAGE IN SHIPMENT. THESE HOLES MAY ALSO BE USED AS THE ATTACHMENT POINT FOR HOOKS WHEN THESE VEHICLES ARE TOWED, AND ANY DAMAGE OTHER THAN SUPERFICIAL DEFORMATION MUST BE REPAIRED. VEHICLES INVOLVED ALL 1980 PHOENIX MODELS ASSEMBLED AT GMAD TARRYTOWN WITHIN THE FOLLOWING PARAMETERS: PLANT BEGINNING VIN UP TO AND INCLUDING 1980 TARRYTOWN SOP 2Y685AT102777

ALSO, INDIVIDUAL VIN 2Z375AT102804 IS INVOLVED.

OWNER NOTIFICATION NO OWNER NOTIFICATION WILL BE REQUIRED SINCE ALL INVOLVED VEHICLES ARE IN DEALER STOCK.

DEALER MODIFICATION RESPONSIBILITY

DEALERS ARE TO PERFORM THIS PRODUCT MODIFICATION ON ALL AFFECTED VEHICLES IN NEW CAR STOCK PRIOR TO VEHICLE SALE.

DEALER ACTION

DEALERS ARE TO INSTALL THE FLOOR PAN CROSS BAR REINFORCEMENT KIT AS DIRECTED IN THE SERVICE PROCEDURE IN THIS BULLETIN. IN ADDITION DEALERS ARE TO INSPECT AND, IF NECESSARY, INSTALL THE FRONT TIE DOWN REINFORCEMENT KIT (RIGHT HAND, LEFT HAND, OR BOTH) AS DIRECTED.

SERVICE PROCEDURE

1. RAISE VEHICLE ON HOIST. DEPENDING ON TYPE OF HOIST USED, POSITION AND ADJUST TWO (2) JACK STANDS AS FOLLOWS: TWIN POST HOIST

POSITION JACK STANDS AT UNDERBODY AREA DIRECTLY BEHIND LEFT AND RIGHT HAND FRONT WHEEL OPENING (FIGURE 1).

"H" HOIST

POSITION JACK STANDS AT LEFT AND RIGHT SIDE RAILS JUST FORWARD OF STABILIZER BAR ATTACHING BRACKETS TO SUPPORT CRADLE.

2. LOOSEN LEFT AND RIGHT FRONT CRADLE BOLTS.

3. REMOVE LEFT AND RIGHT REAR BODY MOUNT BOLTS AND RETAINER PLATES.

4. REMOVE TWO FUEL LINE CLIP MOUNTING SCREWS; ONE LOCATED ADJACENT TO RIGHT REAR BODY MOUNT; A SECOND AT NEXT REARWARD POSITION.

5. DEPENDING ON TYPE OF HOIST USED, LOWER REAR OF CRADLE WITH HOIST OR JACK STANDS SLIGHTLY. POSITION RIGHT REAR REINFORCEMENT PLACE (PART NUMBER 20215001) IN BETWEEN UNDERBODY,FUEL LINE CLIP, AND UPPER BODY MOUNT CUSHION (FIGURE 1). POSITION PLATE SUCH THAT FUEL LINE CLIP ANTIROTATION TANG IS SEATED AND KIT MOUNTING SCREW (PART NUMBER 11500086) CAN BE INSTALLED.

6. LOOSELY INSTALL KIT MOUNTING SCREW (PART NUMBER 11500086) INTO FUEL LINE ANTIROTATION CLIP.

7. REINSTALL RIGHT REAR RETAINER PLATE, AND LOOSELY INSTALL BODY MOUNT CUSHION BOLT.

8. POSITION LEFT REAR REINFORCEMENT PLATE (PART NUMBER 20215002) IN BETWEEN UNDERBODY AND UPPER BODY MOUNT CUSHION, SUCH THAT GAGE HOLE IN PLATE ALIGNS WITH GAGE HOLE IN UNDERBODY AND ENTIRE PLATE IS ON FLAT PORTION OF UNDERBODY.

#### NOTICE: TO INSURE REQUIRED SCREW TORQUE, REINFORCEMENT PLATE MOUNTING HOLES SHOULD NOT ALIGN TO ANY EXISTING HOLES IN UNDERBODY, AS THEY MAY BE TOO LARGE.

9. REINSTALL LEFT REAR RETAINER PLATE AND LOOSELY INSTALL BODY MOUNT CUSHION BOLT.

10. CRADLE TO BODY ALIGNMENT MUST NOW BE ACCOMPLISHED. ALIGN CRADLE BY PLACING 5/8 INCH GAGE RODS IN GAGE HOLES PROVIDED IN CRADLE AND UNDERBODY AT RIGHT FRONT AND RIGHT REAR MOUNT LOCATIONS (FIGURE 2).

#### NOTICE: IT MAY BE NECESSARY TO LOOSEN FOUR (4) STABILIZER BAR ATTACHING BOLTS AND SHIFT BRACKET FORWARD TO CLEAR ALIGNMENT HOLE. ONCE GAGE RODS ARE POSITIONED, STABILIZER BOLTS MAY BE TIGHTENED TO 35-44 FT. LBS. (48-60 NEWTON METERS).

11. TIGHTEN FUEL LINE ANTIROTATION CLIP ATTACHING SCREW (INSTALLED IN STEP 6) TO 7-8 FT. LBS. (9-11 NETWON METERS). MAKE SURE SCREW IS FULLY DRIVEN, SEATED, AND NOT STRIPPED.

12. LIFT CRADLE TO BODY AND TORQUE BODY MOUNTING BOLTS TO 71-85 FT. LBS (95-115 NEWTON METERS) IN COUNTERCLOCKWISE SEQUENCE BEGINNING WITH RIGHT REAR, THEN RIGHT FRONT, THEN LEFT FRONT, THEN LEFT REAR.

13. CENTER PUNCH UNDERBODY THROUGH MOUNTING HOLES IN LEFT AND RIGHT REAR REINFORCEMENT PLATES (TWO IN LEFT PLATE, ONE IN RIGHT PLATE). USING A TAP DRILL 'G' (.261) DRILL THREE MOUNTING HOLES IN UNDERBODY NOT TO EXCEED A DEPTH OF 3/4 INCH. DRILL SIZE STATED MUST BE USED TO INSURE REQUIRED TORQUE ON MOUNTING SCREWS. APPLY ANTI-CORROSION MATERIAL (PART NUMBER 1052290) TO DRILLED AREAS.

14. INSTALL ONE (1) KIT MOUNTING SCREW (PART NUMBER 11500086) IN RIGHT REAR REINFORCEMENT PLATE AND TWO (2) KIT MOUNTING SCREWS (PART NUMBER 11500086) IN LEFT REAR REINFORCEMENT PLATE. TIGHTEN SCREWS TO 7-8 FT. LBS. (9-11 NEWTON METERS). MAKE SURE SCREWS ARE FULLY DRIVEN, SEATED, AND NOT STRIPPED. APPLY ANTI-CORROSION MATERIAL (PART NUMBER 1052290) TO SURFACE OF EACH REINFORCEMENT PLATE.

15. REINSTALL ORIGINAL SCREW IN FUEL LINE CLIP LOCATED REARWARD OF RIGHT REAR BODY MOUNT AND TIGHTEN TO 7-8 FT. LBS. (9-11 NEWTON METERS). MAKE SURE SCREW IS FULLY DRIVEN, SEATED, AND NOT STRIPPED.

16. PULL GAGE RODS FROM RIGHT HAND SIDE AND REMOVE JACK STANDS.

17. INSPECT CONDITION OF UNDERBODY METAL FOR SHIPPING DAMAGE AT THE CARRIER TIE DOWN SLOTS LOCATED DIRECTLY REAR OF LEFT AND RIGHT FRONT WHEELS (SEE FIGURE 3).

INSPECTION A. LIGHT-TO-MODERATE DEFORMATION OF THE AREA AROUND THE SLOTS IS ACCEPTABLE AND REWORK IS NOT REQUIRED. IF THIS IS THE CASE, PROCEED TO STEP 21. B. IF CRACK, TEARS OR ELONGATION OF SLOT(S) EXIST INSTALLATION OF A REINFORCEMENT PLATE IS REQUIRED AT THAT LOCATION ONLY. REFER TO PARTS INFORMATION IN THIS BULLETIN. PROCEED TO STEP 18, IF SUCH DAMAGE IS LESS THAN 3/4" IN LENGTH. C. CONTACT YOUR ZONE REPRESENTATIVE FOR INSTRUCTIONS, IF DAMAGE EXCEEDS 3/4" IN LENGTH.

18. STRAIGHTEN METAL AT LEFT AND/OR RIGHT TIE DOWN SLOT LOCATIONS.

#### NOTICE: IF UNDERBODY CRACKING OR REARING EXTENDS INTO THE HOLE LOCATIONS SHOWN IN FIGURE 4 (TEMPLATE), REPOSITIONING OF HOLES MAY BE REQUIRED TO ATTAIN SOLID ATTACHMENT.

19. CENTER PUNCH AND DRILL FOUR 5/6 INCH HOLES (ONE IN EACH CORNER) IN REINFORCEMENT PLATE(S). PART NUMBER 20213819, LEFT HAND, AND PART NUMBER 20213818, RIGHT HAND (SEE FIGURE 4). DEBURR HOLES.

A. RIGHT SIDE (IF REQUIRED BY STEP 17B) USING REINFORCEMENT PLATE (PART NUMBER 20213818) AS A TEMPLATE, POSITION OVER RIGHT HAND UNDERBODY TIE DOWN SLOT AND SCRIBE (TRACE) ATTACHING HOLE LOCATIONS ON UNDERBODY. B. LEFT SIDE (IF REQUIRED BY STEP 17B) USING REINFORCEMENT PLATE (PART NUMBER 20213819) AS A TEMPLATE, POSITION OVER LEFT HAND UNDERBODY TIE DOWN SLOT AND SCRIBE (TRACE) ATTACHING HOLE LOCATIONS ON UNDERBODY.

20. CENTER PUNCH SCRIBED (TRACED) MARKS COMPLETED IN 19-A AND/OR 19B ABOVE. USING 7/32 INCH DRILL, DRILL ATTACHING HOLES IN UNDERBODY NOT TO EXCEED A DEPTH OF 3/4 INCH. APPLY ANTI-CORROSION MATERIAL (PART NUMBER 1052290) TO DRILLED AREAS AND ANY VISIBLE CRACKS.

A. RIGHT SIDE POSITION REINFORCEMENT PLATE (PART NUMBER 20213818) OVER RIGHT HAND TIE DOWN SLOT AND INSTALL FOUR (4) PART NUMBER 11500086 ATTACHING SCREWS. TIGHTEN TO 7-8 FT. LBS. (9-11 NEWTON METERS). SEE FIGURE 5. APPLY ANTI-CORROSION MATERIAL (PART NUMBER 1052290) TO SURFACE OF REINFORCEMENT PLATE. B. LEFT SIDE POSITION REINFORCEMENT PLATE (PART NUMBER 20213819) OVER LEFT HAND TIE DOWN SLOT AND INSTALL FOUR (4) PART NUMBER 11500086 ATTACHING SCREWS. TIGHTEN TO 7-8 FT. LBS. (9-11 NEWTON METERS). SEE FIGURE 5. APPLY ANTI-CORROSION MATERIAL (PART NUMBER 1052290) TO SURFACE OF REINFORCEMENT PLATE.

21. LOWER VEHICLE.

22. INSPECT AND RESET FRONT END TOE ADJUSTMENT TO SPECIFICATIONS (+.10 DEGREES +.10 DEGREES) (0 INCH + 1/8 INCH).

ENCLOSED WITH YOUR COPY OF THIS LETTER ARE THE FOLLOWING: A LIST OF THOSE VEHICLES INVOLVED WHICH OUR RECORDS INDICATE HAVE BEEN SHIPPED TO YOUR DEALERSHIP IS ATTACHED. ADVISE THE ZONE IF ANY OF THE VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. ANY DEALER NOT RECEIVING A COMPUTER LISTING WAS NOT SHIPPED ANY INVOLVED VEHICLES.

IF A VEHICLE HAS BEEN TRANSFERRED TO ANOTHER LOCATION, PLEASE FORWARD DETAILS OF THE TRANSFER TO YOUR PONTIAC ZONE OFFICE.

PARTS INFORMATION EACH DEALER WILL RECEIVE NO-CHARGE ONE FLOOR PAN CROSS BAR REINFORCEMENT KIT FOR EACH VEHICLE ON THEIR VIN LIST. THIS KIT INCLUDES ONE (1) RIGHT SIDE REINFORCEMENT PLATE, ONE (1) LEFT SIDE REINFORCEMENT PLATE AND FOUR (4) MOUNTING SCREWS.

IF THE CONDITION EXISTS IN THE FRONT TIE DOWN SLOTTED HOLES AS STATED IN SERVICE PROCEDURE, STEP 17-B, THEN PARTS NECESSARY TO CORRECT THE SITUATION ARE TO BE ACQUIRED FROM YOUR PONTIAC ZONE OFFICE. THIS IS A FRONT TIE DOWN REINFORCEMENT KIT, CONSISTING OF EITHER ONE (1) RIGHT HAND TIE DOWN REINFORCEMENT PLATE, ONE (1) LEFT HAND TIE DOWN REINFORCEMENT PLATE AND EIGHT (8) ATTACHING SCREWS. INDICATE WHETHER RIGHT HAND SIDE (PART NUMBER 20213818) OR LEFT HAND SIDE (PART NUMBER 20213819) REINFORCEMENT PLATE OR BOTH IS NEEDED.

#### NOTICE: ONLY A LIMITED NUMBER OF VEHICLES WILL REQUIRE THE FRONT TIE DOWN MODIFICATION.

SPECIFIED ANTI-CORROSION MATERIAL MAY BE OBTAINED THROUGH GENERAL MOTORS PARTS DISTRIBUTION CENTERS. EQUIVALENT (BLACK) ANTI-CORROSION MATERIAL MAY BE USED IF THE SPECIFIED GENERAL MOTORS PART NUMBER 1052290 IS NOT AVAILABLE.

RECORDING COMPLETION

MODIFICATION COMPLETION WILL BE RECORDED FROM PROPERLY COMPLETED AND PAID WARRANTY CLAIMS.

DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER AS FOLLOWS:

(NOTICE: A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION).

WARRANTY CREDIT

A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN. (LABOR) THE NEW LABOR OPERATIONS LISTED BELOW ARE ASSIGNED SPECIFICALLY FOR THIS MODIFICATION.

USE ONLY ONE OF THE LABOR OPERATIONS PER VEHICLE. LABOR TROUBLE DESCRIPTION OPERATION CODE TIME INSTALL R&L REINFORCEMENT KIT E000194 96 1.0 HOURS INSPECT TIE DOWN SLOTS ADDITIONAL MODIFICATION NOT REQUIRED.

INSTALL R&L REINFORCEMENT KIT E000195 96 1.3 HOURS INSTALL ONE SIDE FRONT TIE DOWN SLOT REINFORCEMENT.

INSTALL R&L REINFORCEMENT KIT E111096 96 1.4 HOURS INSTALL BOTH SIDES FRONT TIE DOWN SLOT REINFORCEMENT IN ADDITION, DEALERS WILL AUTOMATICALLY RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATIVE DETAIL ASSOCIATED WITH THIS MODIFICATION.

TROUBLE CODE 96 MUST BE USED WITH THE LABOR OPERATION. THE NECESSARY FLOOR PAN CROSS BAR REINFORCEMENT KIT, AND WHEN NEEDED, THE NECESSARY FRONT TIE DOWN REINFORCEMENT KIT, WILL BE FORWARDED TO DEALERS NO-CHARGE; THEREFORE, PART NUMBERS ARE NOT TO BE LISTED ON THE WARRANTY CLAIM. LIST ONLY THE APPLICABLE AMOUNT SHOWN BELOW UNDER THE NET ITEM COLUMN.

1. CROSS BARR R/F KIT 2. FRT. TIE DOWN R/F KIT 3. FRT. TIE DOWN R/F KIT (ONE SIDE ONLY) (BOTH SIDES)

MATERIAL -$0.65 MATERIAL -$0.75 MATERIAL -$0.85 NET AMOUNT CODE-M NET AMOUNT CODE-M NET AMOUNT CODE-M

THIS REPRESENTS 30% OF THE DEALER PRICE OF THE FURNISHED SERVICE PARTS. DEALERS WILL ALSO RECEIVE $.30 PER VEHICLE FOR ANTI-CORROSION MATERIAL.

(CREDITING)

DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS SHOULD BE CLAIM TYPE 01, CONTAINING ALL INFORMATION REQUIRED FOR A REGULAR CLAIM, AND SHOULD LIST THE LABOR OPERATION AS OUTLINED ABOVE.

REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE MODIFICATION WILL NOT BE PAID.

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.