CAMPAIGN:FUEL LINE ROUTING

PONTIAC CAMPAIGN 94-C-01 CHEVROLET CAMPAIGN 94C09 FUEL LINE ROUTING 1994 CAMARO DATE: DECEMBER 8, 1993

TO: ALL (DIVISION) DEALERS

THE NATIONAL TRAFFIC AND MOTOR VEHICLE 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 OWNER 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 OWNER 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 OWNER AND TO REPAIR THEIR VEHICLE AS SOON AS POSSIBLE. AS YOU WILL SEE IN READING THE ATTACHED COPY OF THE LETTER THAT IS BEING SENT TO OWNERS, THE OWNERS ARE BEING INSTRUCTED TO CONTACT THE (DIVISION) 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 DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN CERTAIN 1994 (DIVISION) FB MODEL VEHICLES WITH 5 7L V8 ENGINES (RPO LT1). THESE VEHICLES MAY HAVE FUEL LINES WHICH CONTACT THE AIR CHECK VALVE, AND THE HIGH TEMPERATURES EXPERIENCED BY THE AIR CHECK VALVE COULD ALLOW IT TO MELT THROUGH A FUEL LINE. IF A FUEL LINE WERE TO DEVELOP A HOLE, AND AN IGNITION SOURCE WAS PRESENT, AN ENGINE COMPARTMENT FIRE COULD OCCUR.

TO PREVENT THIS CONDITION FROM OCCURRING, DEALERS ARE TO INSPECT THE FUEL LINE BUNDLE FOR PROPER ROUTING/ATTACHMENT. MIS-ROUTED FUEL LINE BUNDLES WILL BE REROUTED TO THE PROPER POSITION. ALSO, MIS-ROUTED FUEL LINE BUNDLES WILL BE INSPECTED FOR HEAT DAMAGE AND IF A BUNDLE'S OUTER SHELL HAS BEEN MELTED THROUGH THE BUNDLE WILL BE REPLACED.

VEHICLES INVOLVED

INVOLVED ARE CERTAIN 1994 (DIVISION) FB MODEL VEHICLES WITH 5.7L V8 ENGINES BUILT WITHIN THE FOLLOWING VIN BREAKPOINTS:

YEAR MODEL PLANT CODE FROM THROUGH 1994 F-CAR STE. THERESE "2" R2100381 R2116721 CHEVROLET 1994 F-CAR STE. THERESE "2" R2200132 R2207035 PONTIAC

INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS. COMPUTER LISTINGS CONTAIN THE COMPLETE VEHICLE IDENTIFICATION NUMBER, OWNER NAME AND ADDRESS DATA, AND ARE FURNISHED TO INVOLVED DEALERS WITH THE CAMPAIGN BULLETIN. OWNER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW-UP WITH OWNERS INVOLVED IN THIS CAMPAIGN.

THESE LISTINGS MAY CONTAIN OWNER 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. ANY DEALER NOT RECEIVING A COMPUTER LISTING WITH THE CAMPAIGN BULLETIN HAS NO INVOLVED VEHICLES CURRENTLY ASSIGNED.

OWNER NOTIFICATION

OWNERS WILL BE NOTIFIED OF THIS CAMPAIGN ON THEIR VEHICLES BY CHEVROLET MOTOR DIVISION (SEE COPY OF OWNER 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 OWNERS TAKE POSSESSION OF THESE VEHICLES.

DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO OWNERS, REGARDLESS OF MILEAGE, 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 THE INSTRUCTIONS CONTAINED IN THIS BULLETIN. THIS COULD BE DONE BY MAILING TO SUCH OWNERS A COPY OF THE OWNERS 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 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.

PARTS INFORMATION

PARTS REQUIRED TO COMPLETE THIS CAMPAIGN ARE TO BE OBTAINED FROM GENERAL MOTORS SERVICE PARTS OPERATIONS (GMSPO). TO ENSURE THESE PARTS WILL BE OBTAINED AS SOON AS POSSIBLE, THEY SHOULD BE ORDERED FROM GMSPO ON A "C.I.O." ORDER WITH NO SPECIAL INSTRUCTION CODE, BUT ON AN ADVISE CODE (2).

QUANTITY/ PART NUMBER DESCRIPTION VEHICLE

10258441 FUEL LINE ASSEMBLY AS REQUIRED

11509088 TIE STRAP AS REQUIRED

SERVICE PROCEDURE

1. INSPECT FUEL LINE BUNDLE TO AIR VALVE CLEARANCE THERE SHOULD BE 25MM (1 INCH) OF CLEARANCE BETWEEN THE AIR VALVE AND THE FUEL LINE BUNDLE (SEE FIGURE 1 BELOW).

IF THERE IS NOT 25MM (1 INCH) OF CLEARANCE, SLIDE RETAINING STRAP (#2 IN FIGURE 1) FORWARD AND AWAY FROM THE AIR VALVE UNTIL 25MM (1 INCH) CLEARANCE HAS BEEN CREATED AND PROCEED TO STEP 2 ON NEXT PAGE.

IF 25MM (1 INCH) CLEARANCE ALREADY EXISTS, NO FURTHER ACTION IS REQUIRED. PROCEED TO STEP 24.

2. INSPECT FUEL LINE BUNDLE FOR SIGNS OF HEAT DAMAGE.

- IF OUTER CONDUIT SHELL OF BUNDLE HAS BEEN MELTED THROUGH, THE BUNDLE MUST BE REPLACED. CONTINUE TO STEP 3.

- IF THE OUTER CONDUIT SHELL HAS NOT BEEN MELTED THROUGH, NO FURTHER ACTION IS REQUIRED. PROCEED TO STEP 24.

NOTICE: FIGURE 13 ON PAGE 6C-16 OF 1994 CAMARO/FIREBIRD SERVICE MANUAL (BOOK 1) MAY BE HELPFUL IN PERFORMING THIS PROCEDURE.

ALSO, CLEAN ALL ENGINE COMPARTMENT FUEL PIPE CONNECTIONS AND SURROUNDING AREAS BEFORE DISCONNECTING TO AVOID POSSIBLE CONTAMINATION OF FUEL SYSTEM.

3. RELIEVE FUEL SYSTEM PRESSURE PER SERVICE MANUAL PROCEDURES.

4. DISCONNECT NEGATIVE BATTERY CABLE (FIRST NOTE RADIO SETTINGS SO THEY MAY BE RESET LATER).

5. DRAIN FUEL TANK.

6. DISCONNECT QUICK-CONNECT FITTINGS AT ENGINE FUEL PIPES (INCLUDING EVAPORATIVE EMISSION PIPE).

7. DISCONNECT FUEL PIPES FROM ROUTING CLIPS AND REMOVE FUEL PIPE GROMMET FROM WHEEL HOUSING.

8. RAISE VEHICLE IF USING A FRAME CONTACT HOIST, POSITION FRONT HOIST ARMS INSIDE OF THE VEHICLE'S PLASTIC JACK/HOIST PADS ON THE VEHICLE UNDERCARRIAGE THE DRIVER'S SIDE PAD WILL BE REMOVED IN STEP 10.

9. UNBOLT LEFT HAND WHEELHOUSE PANEL AND REPOSITION SO THAT FUEL LINES INSIDE OF WHEEL HOUSING CAN BE ACCESSED.

10. REMOVE LEFT HAND PLASTIC JACK/HOIST PAD.

11. DISCONNECT QUICK-CONNECT FITTINGS AT CHASSIS FUEL PIPES.

12. REMOVE FUEL PIPES FROM CLIPS AND ROUTING BRACKET, AND REMOVE PIPES FROM VEHICLE.

13. INSTALL NEW FUEL PIPES TO CLIPS AND ROUTING BRACKET.

14. CONNECT QUICK-CONNECT FITTINGS AT CHASSIS FUEL PIPES.

15. REINSTALL LEFT HAND PLASTIC JACK/HOIST PAD.

16. REINSTALL LEFT HAND WHEEL HOUSE PANEL.

17. LOWER VEHICLE.

18. CONNECT FUEL PIPES TO ROUTING CLIPS AND INSTALL FUEL PIPE GROMMET TO WHEEL HOUSING.

19. CONNECT QUICK-CONNECT FITTINGS AT ENGINE FUEL PIPES (INCLUDING EVAPORATIVE EMISSION PIPE).

20. ATTACH RETAINING STRAP AS SHOWN IN FIGURE 1, PAGE 3 AND ASSURE THAT PROPER 25MM (1 INCH) CLEARANCE EXISTS.

21. REFILL FUEL TANK.

22. RECONNECT NEGATIVE BATTERY CABLE (ALSO RESET RADIO SETTINGS AND CLOCK).

23. TURN IGNITION SWITCH TO "ON" POSITION FOR 2 SECONDS, THEN TURN TO "OFF" POSITION FOR 10 SECONDS. AGAIN TURN IGNITION TO "ON" POSITION AND CHECK PIPES FOR FUEL LEAKS.

24. INSTALL 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 FOR PERIODIC SERVICING BY THE OWNER. ADDITIONAL "CAMPAIGN IDENTIFICATION LABELS" CAN BE OBTAINED FROM DAC.

APPLY "CAMPAIGN IDENTIFICATION LABEL" ONLY ON A CLEAN, DRY SURFACE.

CLAIM INFORMATION

SUBMIT A PRODUCT CAMPAIGN CLAIM WITH THE INFORMATION INDICATED BELOW: * FAILED FAILED CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO ALLOW OP HRS HRS

INSPECT/NO ACTION REQUIRED - SK-00 V8390 0 2 0 1

INSPECT/REROUTE BUNDLE - NO MELT - THROUGH OF BUNDLE SK-00 V8391 0 2 0 1

INSPECT/REPLACE 2 10258441 SK-00 V8392 1 1 0 1 REROUTE BUNDLE

NOTE: PONTIAC FAILURE CODE 96

* CAMPAIGN ADMINISTRATIVE ALLOWANCE

** THE "PARTS ALLOWANCE" SHOULD BE THE SUM TOTAL OF THE CURRENT GMSP OF ALL PARTS REQUIRED FOR THE REPAIR.

DEALERS WILL AUTOMATICALLY RECEIVE THE CORRECT LABOR AND MATERIAL ALLOWANCE BASED ON THE LABOR OPERATION PERFORMED.

REFER TO THE (DIVISION) CLAIMS PROCESSING MANUAL FOR DETAILS ON PRODUC CAMPAIGN CLAIM SUBMISSION.

----- SAMPLE LETTER ----- (NOTIFICATION USED BY CHEVROLET MOTOR DIVISION)

DECEMBER 8, 1993

DEAR CHEVROLET CAMARO OWNER:

THIS NOTICE IS SENT TO YOU IN ACCORDANCE WITH THE REQUIREMENTS OF THE NATIONAL TRAFFIC AND MOTOR VEHICLE SAFETY ACT.

REASON FOR THIS RECALL

GENERAL MOTORS HAS DETERMINED THAT A DEFECT WHICH RELATES TO MOTOR VEHICLE SAFETY EXISTS IN CERTAIN 1994 CHEVROLET CAMARO MODEL VEHICLES WITH 5 7L V8 ENGINES (RPO LT1). THESE VEHICLES MAY HAVE FUEL LINES WHICH CONTACT THE AIR CHECK VALVE, AND THE HIGH TEMPERATURES EXPERIENCED BY THE AIR CHECK VALVE COULD ALLOW IT TO MELT THROUGH A FUEL LINE. IF A FUEL LINE WERE TO DEVELOP A HOLE, AND AN IGNITION SOURCE WAS PRESENT, AN ENGINE COMPARTMENT FIRE COULD OCCUR.

WHAT WE WILL DO

TO PREVENT THIS CONDITION FROM OCCURRING, YOUR DEALER WILL INSPECT THE FUEL LINE BUNDLE FOR PROPER ROUTING/ATTACHMENT. MIS-ROUTED FUEL LINE BUNDLES WILL BE REROUTED TO THE PROPER POSITION. ALSO, MIS-ROUTED FUEL LINE BUNDLES WILL BE INSPECTED FOR HEAT DAMAGE AND IF A BUNDLE'S OUTER SHELL HAS BEEN MELTED THROUGH THE BUNDLE WILL BE REPLACED. THIS SERVICE WILL BE PERFORMED FOR YOU AT NO CHARGE.

WHAT YOU SHOULD DO

PLEASE CONTACT YOUR CHEVROLET DEALER AS SOON AS POSSIBLE TO ARRANGE A SERVICE DATE AND SO THE DEALER MAY ORDER THE NECESSARY PARTS FOR THE REPAIR. INSTRUCTIONS FOR MAKING THIS INSPECTION/CORRECTION HAVE BEEN SENT TO YOUR DEALER AND PARTS ARE AVAILABLE. THE LABOR TIME NECESSARY TO PERFORM THIS SERVICE CORRECTION IS APPROXIMATELY 10 MINUTES TO ONE HOUR. PLEASE ASK YOUR DEALER IF YOU WISH TO KNOW HOW MUCH ADDITIONAL TIME WILL BE NEEDED TO SCHEDULE AND PROCESS YOUR VEHICLE.

YOUR CHEVROLET DEALER IS BEST EQUIPPED TO OBTAIN PARTS AND PROVIDE SERVICE TO ENSURE THAT YOUR VEHICLE IS CORRECTED AS PROMPTLY AS POSSIBLE. IF, HOWEVER, YOU TAKE YOUR VEHICLE TO YOUR DEALER ON THE AGREED SERVICE DATE, AND THEY DO NOT REMEDY THIS CONDITION ON THAT DATE OR WITHIN FIVE (5) DAYS, WE RECOMMEND YOU CONTACT THE CHEVROLET CUSTOMER ASSISTANCE CENTER BY CALLING 1-800-222-1020.

AFTER CONTACTING YOUR DEALER AND THE CUSTOMER ASSISTANCE CENTER, 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 WISH TO WRITE THE ADMINISTRATOR, NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION, 400 SEVENTH STREET, S W , WASHINGTON, D.C. 20590 OR CALL 1-800-424-9393 (WASHINGTON D.C. RESIDENTS USE 366-0123).

THE ENCLOSED OWNER REPLY CARD IDENTIFIES YOUR VEHICLE. PRESENTATION OF THIS CARD TO YOUR DEALER WILL ASSIST IN MAKING THE NECESSARY INSPECTION/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 IN THE INTEREST OF YOUR SAFETY AND CONTINUED SATISFACTION WITH OUR PRODUCTS.

CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION

ENCLOSURE

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.