CAMPAIGN: ENGINE FUEL LEAKAGE AT TBI FUEL PIPE CONNECTION. Pontiac J2000 1983

For 1990-2009 cars

# CAMPAIGN: ENGINE FUEL LEAKAGE AT TBI FUEL PIPE CONNECTION

THE NATIONAL TRAFFIC AND MOTOR VEHCILE SAFETY ACT, AMENDED, PROVIDES THAT EACH VEHICLE WHICH IS SUBJECT TO A RECALL CAMPAIGN OF THIS TYPE MUST BE ADEQUATELY REPAIRED WITHIN A RESONABLE TIME AFTER THE OWNER HAS TENDERED IT FOR REPAIR. A FAILURE TO ADEQUATELY REPAIR WITHIN 60 DAYS AFTER TENDER OF A VEHCILE 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 REASONALBE 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 WHICH IS BEING SENT TO OWNERS, THE OWNERS ARE BEING INSTRUCTED TO CONTACT THE NEAREST PONTIAC ZONE OFFICE IF THEIR DEALER DOES NOT REMEDY THE CONDITION WITHIN FIVE 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 EARLY PRODUCTION 1983 PONTIAC 2000 MODELS EQUIPPED WITH 2.0L ENGINES (UPC LQ5). THE FUEL SYSTEM IN THESE VEHICLES MAY LEAK AT THE THROTTLE BODY INJECTION FUEL FEED PIPE CONNECTION. UNDER CERTAIN CONDI- TIONS THIS COULD RESULT IN AN UNDERHOOD FIRE. SUCH A FIRE COULD, IN TIME, SPREAD TO THE PASSENGER COMPARTMENT AND CAUSE BURN INJURIES TO OCCUPANTS REMAINING IN THE VEHICLE. VEHICLES INVOLVED INVOLVED ARE CERTAIN EARLY PRODUCTION 1983 PONTIAC 2000 MODELS EQUIPPED WITH UPC LQ5 (2.0L 4-CYLINDER TBI ENGINE) VIN CODE P, AND IDENTIFIED WITHIN THE FOLLOWING VEHICLE BREAKPOINTS: PLANT BEGINNING VIN UP TO AND INCLUDING LORDSTOWN D7200059 D7204407 SOME VEHICLES WITH VIN'S WITHIN THE ABOVE LISTED RANGE OF NUMBERS WERE CORRECTEC AT THE ASSEMBLY PLANT AND WILL NOT APPEAR ON THE PRINTOUT. DEALER CAMPAIGN RESPONSIBILITY DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNERSHIP, FROM THIS TIME FORWARD. WHENEVER A VEHICLE SUBJECT TO THIS CAMPAIGN IS TAKEN IN TO YOUR NEW OR USED VEHICLE INVENTORY OR IT IS IN YOUR DEALESHIP FOR SERVICE IN THE FUTURE, YOU SHOULD TAKE THE STEPS NECESSARY TO BE SURE THE CAMPAIGN CORRECTION HAS BEEN MADE. OWNER NOTIFICATION OWNERS OF VEHICLES INVOLVED IN THIS CAMPAIGN, WHOSE NAMES ARE ON RECORD AT THE TIME THE DATA IS PREPARED, WILL BE NOTIFIED BY PONTIAC MOTOR DIVISION (SEE COPY OF OWNER LETTER INCLUDED WITH THIS BULLETIN.) INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER COMPUTER LISTINGS CONTAIN THE COMPLETE VEHICLE IDENTIFICATION NUMBER, OWNER NAME AND ADDRESS DATA, AND ARE FURNISHED TO THE INVOLVED DEALES WITH THE CAMPAIGN BULLETIN. OWNER NAME AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW UP WITH OWNERS INVOLVED IN THIS CAMPAIGN. SERVICE PROCEDURE CAUTION: TO REDUCE THE RISK OF FIRM AND PERSONAL INJURY, IT IS NECESSARY TO RELIEVE THE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. TO DO THIS: A. REMOVE FUSE MARKED "FUEL PUMP" FROM FUSE BLOCK IN PASSENGER COMPARTMENT. B. CRANK ENGINE - ENGINE WILL START AND RUN UNTIL FUEL SUPPLY REMAINING IN FUEL LINES IS CONSUMED. WHEN ENGINE STOPS, ENGAGE STARTER AGAIN FOR 3.0 SECONDS TO ASSURE RELIEF OF ANY REMAINING PRESSURE. C. WITH IGNITION "OFF," REPLACE "FUEL PUMP" FUSE.

1. REMOVE AIR CLEANER COVER (PLASTIC) AND AIR CLEANER ASSEMBLY (SEE FIG.1 ON PAGE 3). 2. INSPECT THE GOLD COLORED BOLT WHICH ATTACHES THE BANGO FITTING TO THE TBI UNIT (SEE FIG.2 ON PAGE 3.) IF THE BOLT HEAD HAS A BLACK STRIPE OR BLACK PAINT, REINSTALL THE AIR CLEAN- ER AND AIR CLEANER COVER AND PROCEED TO STEP NUMBER 15. 3. REMOVE DISTRIBUTOR CAP AND ROTOR. 4. REMOVE FUEL SUPPLY LINE BANGO FITTING BOLT FROM TBI UNIT AND TWO NYLON SEALING WASHERS (INBOARD AND OUTBOARD). DISCARD BOLT AND WASHERS (REFER TO FIG.2). CARE SHOULD BE TAKEN SO THAT FUEL SUPPLY LINE IS NOT DEFORMED. THIS WILL EASE INSTALLATION OF NEW PARTS. 5. INSTALL ONE NEW LEAD COATED WASHER (GASKET) ON A NEW BOLT (BLACK PAINT ON HEAD) AND INSERT INTO BANGO FITTING (REFER TO FIG.2.) 6. INSTALL SECOND LEAD COATED WASHER BETWEEN BANJO FITTING AND INJECTOR BODY (REFER TO FIG.2) ON A "HOT TO TOUCH"ENGINE, IT MAY BE NECESSARY TO PULL FUEL LINE TOWARDS THROTTLE CABLE RETAINER BRACKET AND INSTALL GASKET OVER BANGO FITTING BOLT. DO NOT DEFORM FUEL LINE AS MISALIGNMENT BETWEEN BANGO AND TBI SEAL SURFACE MAY OCCUR. 7.THREAD BANJO FITTING BOLT INTO INJECTOR BODY. VERIFY THAT WASHERS ARE IN THE CORRECT POSITION BEFORE TORQUING. DO NOT LUBE GASKETS OR BOLT THREADS. 8. ATTACH KENT-MOORE TOOL #J34062 (1983 ESSENTIAL TOOL) ON A POINTER READ- OUT BEAM TYPE TORQUE WRENCH. DO NOT USE A "CLICKER" OR A DIAL (CIRCULAR READ- OUT) TYPE TORQUE WRENCH (SEE FIGS. 3 AND 4 ON THE FOLLOWING PAGE.) 9. TORQUE BANJO FITTING BOLT 33NOM (24.FT LBS. AND 288 IN. LBS.). NOTICE: IT IS IMPORTANT THAT TORQUE BE APPLIED AT A SLOW AND CONSTANT RATE. OVERTORQUE MAY RESULT IN BOLT FAILURE. 10. REINSTALL ROTOR AND DISTRIBUTOR CAP. 11. PLUG OPEN VACUUM FITTING ON INLET MANIFOLD VACUUM TREE. 12. START ENGINE AND CHECK FOR FUEL LEAKS. 13. REMOVE VACUUM PLUG. 14. INSTALL AIR CLEANER ASSEMBLY MAKING SURE VACUUM SUPPLY LINE RUNNING FROM AIR CLEANER RETAINER CLIP TO THERMAC TEMPERATURE SWITCH IS NOT PINCHED BET- WEEN AIR CLEANER AND TBI ISOLATOR UNIT (REFER TO FIG.1). ASSURE THAT: (1) FRESH AIR SUPPLY HOSE; (2) CRANKCASE VENTILATION HOSE; (3) HEAT STOVE TUBE ARE REATTACHED TO BASE OF AIR CLEANER ASSEMBLY. 15. EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUTLINED IN THIS SERVICE PROCEDURE WILL REQUIRE A CAMPAIGN IDENTIFICATION LABEL. EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER, THE FIVE DIGIT DEAL- ER CODE OF THE DEALER PERFORMING THE CAMPAIGN SERVICE, AND THE DATE VEHICLE WAS CAMPAIGNED. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALL- POINT PEN. INSTALL THE LABEL ON THE RADIATOR BAFFLE WHERE IT IS READILY VISIBLE. PARTS INFORMATION THE PARTS REQUIRED TO COMPLETE THIS MODIFICATION ARE BEING DISTRIBUTED FROM PONTIAC CENTRAL OFFICE AS PARTS BECOME AVAILABLE. PARTS WILL BE FURNISHED TO INVOLVED DEALERS ON A NO CHARGE BASIS. PART NUMBER QUANTITY DESCRIPTION 14069078 1 PER VEHICLE BOLT 14072733 2 PER VEHICLE WASHER (GASKET) PARTS ARE NOT TO BE ORDERED OR RETURNED TO WDDGM. ENCLOSED WITH THE COPY OF THIS BULLETIN A LIST OF THOSE VEHCILES INVOLVED, WHICH OUR RECORDS INDICATE ARE IN YOUR GEOGRAPHICAL AREA, IS ATTACHED FOR YOUR FOLLOW-UP. ADVISE THE ZONE IF VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. (IF A LIST OF VEHICLES, IS NOT ATTACHED, OUR RECORDS INDICATE NO AFFECTED VEHICLE(S) IN YOUR AREA.) IF A VEHICLE HAS BEEN TRANSFERRED OR SOLD TO ANOTHER LOCATION, PLEASE FORWARD THE NEW NAME AND ADDRESS OF THE VEHICLE TO YOUR PONTIAC ZONE OFFICE. RECORDING COMPLETION CAMPAIGN COMPLETION WILL BE RECORDED FORM "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." OWNERS ARE BEING ASKED TO PRESENT THE OWNER REPLY CARD FOR IDENTIFICATION TO THEIR DEALER AT THE TIME THEY BRING IN THEIR VEHICLE TO HAVE THE CAMPAIGN PERFORMED. ADDITIONAL CAMPAIGN LABELS ARE AVAILABLE ON STATIONERY ORDER AS FORM 7201-709 DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: (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 VEHICLE. DESCRIPTION FAILURE CODE LABOR OPERATION LABOR HOURS OTHERS LABOR HOURS INSPECT BANJO 96 V1390 0.2 HR 0.1HR FITTING BOLT NO FURTHER ACTION INSTALL NEW BANJO 96 V1391 0.3HR. 0.1 HR BOLT & TWO NEW WASHERS (GASKET) ** IN ADDITION, DEALERSHIPS WILL RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATIVE SERVICES ASSOCIATED WITH THIS CAMPAIGN. THE 0.1 HOURS ALLOW- ANCE IS TO BE ENTERED IN THE "OTHER LABOR HOURS" FIELD WITH EACH CAMPAGIN REPAIR LISTED FOR CREDIT. THIS ENTRY WILL NOT REQUIRE ZONE AUTHORIZATION. FAILUR CODE 96 MUST BE USED WITH THE LABOR OPERATION. (CREDITING) DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION, WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION FOR PAYMENT. CLAIMS MUST CONTAIN ALL INFORMATION REQUIRED AND SHOULD LIST THE LABOR OPERATION AS OUTLINED. REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE CAMPAIGN 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.