9 - FieroNews
Contents
1. Hose TBI Coolant Replace Relay Engine Blower Motor and or Fan Engine Blower Labor Hours T el 6 N e e w n gt gt I gt to E w 2 4 LUBRICATION SYSTEM Rocker Gasket Right Rear Left Forward Both 2 0 2 3 2 6 CONTINUED Labor Operation T3203 T3204 T3205 T3206 T1830 T3213 T3215 T3216 T3242 T3229 T3232 T3233 T3234 T3235 T3236 T3237 T1631 T1632 T1633 T1634 T1635 T1636 CLAIM INFORMATION Continued FUEL SYSTEM Seals Fuel Feed amp Return Pipes J T1637 Pipe Fue Pump to Throttle Body Unit Repl 3 T3312 Pipe Fuel Repair 6 T1626 O Ring Cold Start Valve Replace 1 0 T1838 TRANSMISSION OIL COOLER Upper Trans 011 Cooler Hose Replace 2 T3180 Lower Trans 011 Cooler Hose Replace 2 T3181 Both Trans Oil Cooler Hose Replace 3 T3182 IGNITION SYSTEM ENGINE COMPARTMENT WIRING Wiring Routing Clips 2 71627 BOLT BREAKAGE Exhaust Manifold Each Bolt Stud 6 T1639 CAR RENTAL Car Rental Parts Delay T3256 NOTE CAR RENTAL up to 30 00 per day f for a maximum of 2 days IS TO COVER PARTS DELAYS CLAIMS IN EXCESS OF AND AUTHORIZATION 2 DAYS WILL REQUIRE ZONE REVIEW NOTE FAILURE CODE 95 MUST BE USED WITH ANY OF THE FOLLOWING T LABOR OPERATIONS Dealers will be credited via Warranty Document or Terminal Transmission whichever is their normal method of submission for payment Claim must con2. Pontiac dealer for information on whether your vehicle may benefit from the information Owner Letter August 1990 Dear Pontiac Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act REASON FOR RECALL General Motors has determined that a defect which relates to motor vehicle safety exists in 1985 88 Pontiac Fiero model vehicles with 2 8L V6 engines An interaction of the engine compartment environment in 1985 88 Pontiac Fiero s and maintenance or service related factors results in the potential for engine compartment fire 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 WHAT WE WILL DO 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 deflector installed a minor change to decklid sealing and a general inspection and repair as necessary of underhood fluid and wiring systems Additionally 1985 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 WHAT YOU SHOULD DO Please contact your Pontiac dealer as soon as possible to arrange a service date Instructions for making this correction ha
3. and repaired if necessary Inspect cooling fan operation on 1985 87 the engine compartment blower fan also should be inspected Replacement of relay coolant switch wiring or fan is authorized to make functional Install engine compartment lid Install campaign identification label Campaign Identification Label PONTIAC CAMPAIGN mw 99020 cone 2O COO DATE 5 DO NOT REMOVE 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 the five 5 digit dealer code of the dealer perfoming the campaign service and the date the vehicle was campaigned This information may be inserted with a typewriter or a ball point pen Install the label only on underside of decklid where it is readily visible additional campaign labels are available on stationary order as Form 7901 709 Claim Information Other Failure Labor Labor Operation Code Operation Hours Hours Install Deflector Pkg 96 V6140 3 1 0 1 Vehicle without A C 1985 88 Install Deflector Pkg 96 V6141 5 0 0 1 Vehicle with 1985 88 Owner Reimbursement On Previous Repairs 96 6142 ss The labor hours above include time for pressurizing and inspecting the cooling and fuel system In addition dealership will receive 0 1 hours credit for dealer admini strative services associat
4. clamps and hoses at engine and air cleaner DO NOT remove PCV vent tube mounted on forward engine compartment wall Apply penetrating oil to all bolts and studs of the forward exhaust manifold THIS STEP IS VERY IMPORTANT TO AVOID STUD BREAKAGE LATER ON Remove exhaust manifold to crossover bolts Disconnect upper engine strut g Raise vehicle h Remove convertor down pipe to crossover bolts 1 Remove convertor heat shield Perform the following steps on air conditioned vehicles 1 Remove air conditioning compressor shield 2 Disconnect A C belt and wires from compressor 3 Remove A C compressor mount bolts and lower A C adjusting bracket 4 Lower vehicle 5 Remove upper A C compressor mount bracket 6 Raise vehicle k Install jack stands under rear of vehicle to allow cradle to be lowered slightly l Install jack stand under cradle and remove forward cradle bolts and nuts lower cradle slowly approximately SIX 6 inches below mountings for better access to front exhaust manifold Do not lower more than SIX 6 inches m Remove outer exhaust manifold heat shield n Remove forward manifold bolts and studs Best results will be obtained by Applying penetrating oil early step c and reapply now In the event of bolt breakage a service tool for piloting easyouts WITHOUT removing the cylinder head has been provided Kent Moore Tool J 38782 has been provided to all involved dealers Clean exhaust manifol
5. 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 1985 88 Pontiac Fiero Model vehicles with 2 8L V6 engines RPO L44 An interaction of the engine compartment environment in 1985 86 Pontiac Fiero s 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 greatly reduce the possibility of this condition occurring all vehicles will have changes made in their underhood environment Specifically all vehicles will have a manifold deflector installed a minor change to decklid sealing a PCV system modification and a general inspection and repair as necessary of underhood fluid and wiring systems Additionally 1985 86 model year vehicles will have a new exhaust manifold installed to bring them up to 1987 88 specifications Vehicles Involved Up To And Model Year Plant Beginning Including P 1985 Pontiac FP200001 FP276370 P 1986 Pontiac GP200006 GP283973 P 1987 Pontiac 200006 246579 1988 Pontiac JP200003 JP226402 Involved are 1985 88 Pontiac Fiero Model vehicles with 2 8L V6 engine RPO L44 produced within the following VIN breakpoints Involved vehicl
6. BOLT SCREW EXHAUST MANIFOLD M8 X 1 25 X 50 NUT EXHAUST SHIELD GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT BOLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 d Nd ILLUSTRATION 1987 88 KIT Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations GMSPO To ensure that 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 Service Procedure To reduce the effects of fluid leaks which may lead to engine compartment fires Pontiac dealers will do the following at no charge l INSTALL EXHAUST MANIFOLD DEFLECTOR a Remove outboard grille panels and disconnect BOTH positive and negative battery cables remove the battery on vehicles equipped with air conditioning REMOVE ATTACHING HARDWARE REMOVE AND DISCARO RUBBER DUST SEAL ILLUSTRATION C DECK LID b Remove rear encine compartment lid Remove rubber dust seal and retaining clips from leading edge front of decklid assembly and leave off ILLUSTRATION C REMOVE SEAL view ILLUSTRATION D AIR INTAKE DUCT SYSTEM 1985 86 DO NOT REMOVE FROM VEHICLE view B ILLUSTRATION E AIR INTAKE DUCT SYSTEM 1987 88 Remove air intake duct assembly ILLUSTRATION D amp E Remove foam rubber seal on air cleaner housing neck 85 86 only Remove PCV vent tube elbow s
7. TRATION F and install outer manifold heat shield dimensions for modification on illustration s Reattach cradle and torque cradle bolts according to the applicable Fiero Service Manual procedure Remove jack stands Lower vehicle Nd PARTS IDENTIFICATION 6 CYL NAME DEFLECTOR ASM VLV RKA CVA OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD 8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END BOLT SCREW EXHAUST MANIFOLD X 1 25 X 50 NUT EXHAUST SHIELD MANIFOLD ASM EXHAUST GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT POLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 ILLUSTRATION A 1985 86 KIT PARTS IDENTIFICATION 6 CYL NAME DEFLECTOR ASM RKR CVA OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD 8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END BOLT SCREW EXHAUST MANIFOLD M8 X 1 25 X 50 NUT EXHAUST SHIELD GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT BOLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 d Nd ILLUSTRATION 1987 88 KIT t Install crossover to manifold bolts using torque values described in ILLUSTRATION A amp B u Install upper A C compressor mount bracket v Install side heat shield A C equipped vehicles and install battery to be connected later w Raise vehicle X Install A C com
8. Technical Service Bulletin 88C24 Date 900601 Potential For Engine Compartment Fires Campaign 88 C 24 Number 88 24 Date June 90 PRODUCT SAFETY CAMPAIGN 88 C 24 Subject LACK OF ADEQUATE SERVICE OR MAINTENANCE MODELS AFFECTED 1985 88 PONTIAC FIERO MODELS WITH 2 8L V6 ENGINES RPO L44 TO ALL PONTIAC 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 adequately repair within sixty 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 which is being sent to owners the owners are being instructed to contact the Pontiac Customer Assistance Center 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 owners are
9. d gasket surfaces Inspect 1987 88 exhaust manifold for any evidence of cracking or significant warpage The 1985 86 vehicles will have a new slotted flange manifold installed 1f not already equipped Cut wire harness bracket off engine coolant pipe to avoid interference with new shield PARTS IDENTIFICATION 6 CYL E NAME DEFLECTOR ASM VLV RKR CVR OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD M8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END BOLT SCREW EXHAUST MANIFOLD X 1 25 X 50 NUT EXHAUST SHIELD MANIFOLD ASM EXHAUST GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT ROLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 Rem NONU e M o oO M OQ t ILLUSTRATION A 1985 86 KIT PARTS IDENTIFICATION 6 CYL NAME DEFLECTOR ASM RKR CVA OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD 8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END BOLT SCREW EXHAUST MANIFOLD M8 X 1 25 X 50 NUT EXHAUST SHIELD GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT BOLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 d Nd ILLUSTRATION 1987 88 KIT q Stack manifold deflector gasket and manifold over new bolts and install position on head using top bolts using torque values described in ILLUSTRATION A amp B ILLUSTRATION F MANIFOLD HEAT SHIELD r Modify ILLUS
10. e inventory are to be contacted by the dealer and arrangements made to make the required correction according to instructions contained in this bulletin Parts Information Part Quantity Description Number Vehicle Service Kit 1985 86 ILLUSTRATION A 10154785 1 Service Kit 1987 88 ILLUSTRATION B 10154787 1 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 from GMSPO as required from the appropriate service parts catalog Please note also that campaign 86 C 13 ENGINE SPLASH SHIELDS POTENTIAL INTERFERENCE WITH COOLANT HOSES should also be done if it is still outstanding EOS S ee ae E T A c NO C 2 2 PARTS IDENTIFICATION 6 CYL NAME DEFLECTOR ASM VLV RKR CVR OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD 8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END BOLT SCREW EXHAUST MANIFOLD X 1 25 X 50 NUT EXHAUST SHIELD MANIFOLD ASM EXHAUST GROMMET CRANKCASE VENT TUBE TUBE ASM CRANKCASE VENT POLT SCREW CRANKCASE VENT TUBE M10 X 1 5 X 16 ILLUSTRATION A 1985 86 KIT PARTS IDENTIFICATION 6 CYL NAME DEFLECTOR ASM RKR CVA OIL LH GASKET EXHAUST MANIFOLD BOLT SCREW EXHAUST MANIFOLD 8 X 1 25 X 26 STUD EXHAUST MANIFOLD X 1 25 X 26 STUD END
11. ed with this campaign The 0 1 hours allowance is to be entered in the Other Labor Hours field with each campaign repair listed for credit This entry will not require authorizatian A separate repair order must be kept for each vehicle A completed warranty claim is to be kept as a pemanent record of completion DEALERS SHOULD SUBMIT VIARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS FAILURE CODE 96 MUST BE USED WITH THESE LABOR OPERATIONS IF THE INSPECTION PROCEDURE REVEALS ADDITIONAL OPERATIONS ARE NECESSARY THE APPROPRIATE T LABOR OPERATIONS SHOULD BE SELECTED FROM FOLLOWING CHARTS THESE SHOULD ONLY BE USED IN CONJUNCTION WITH V6140 AND V6141 EXHAUST SYSTEM Labor Labor Description Hours Operation Shield Exhaust Replace 3 73244 Each Additional 2 Crossover Pipe 5 T1629 CLAIM INFORMATION Continued COOLING SYSTEM Description Clamp Radiator Hose Replace Add To Replace Each Addt l Coolant Hoses Replace Upper Coolant Hoses Replace Lower Replace Both Upper amp Lower Pump Gasket Coolant Replace Sensor Coolant Temperature Coolant Fan Switch Replace Engine Coolant Temp Switch Replace Thermostat Housing and or Gasket Replace Heater Pipe Clamp Replace Hose Htr Pipe to Eng Comp Inlet Rep Hose Eng Comp Inlet to Engine Repl Hose Htr Pipe to Engine Outlet Repl Blade Motor Cooling Fan Replace Relay Cooling Fan Replace Wiring and or Connector Repair
12. es 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 reason 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 Pontiac Division see copy of owner letter included with this bulletin Dealer Campaign Responsibility 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 Whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory or it is dealership tor service in the future you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle Owners of vehicles recently sold from your new vehicl
13. ontinued satisfaction with our products
14. pressor attach wires lower adjusting bracket and belt do adjustment at this time y Install convertor down pipe to crossover bolts installing new seal provided in the kit 7 Install compressor heat shield equipped vehicles convertor heat shield NOTE THE 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 ii PRIOR TO PERFORMING THESE INSPECTIONS THE TRAINING VIDEO WINNERS DO IT RIGHT MAILED SEPT 1989 SHOULD BE VIEWED 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 ZONE CONTACT PERSON WITH SERVICE RESPONSIBILITY aa Conduct inspection underneath the vehicle for Any indication of transmission oil cooler hose leakage n Interference between right hand wheelhouse splash shield and coolant hose IF CAMPAIGN 86 C 13 HAS NOT BEEN PERFORMED DO IT NOW MUFFLER CONVERTER HEAT SHIELD ILLUSTRATION G HEAT SHIELD ARTWORK ILLUSTRATION H PLUG WIRE CLIP bb Lower vehicle Remove plug wire clip slide conduit up and rein stall clip connect wires to spark plugs ILLUSTRATION The clip is no longer seated on the bracket and should be reposi
15. re Gauge Pressurize fuel system to approximately 40 psi by running fuel pump with key on Using pressure gage on schrader valve monitor to check If system holds pressure Observe coldstart and port injector connections at fuel rail as well as coupled fuel hose fittings for any sign of leakage Repair as necessary Pkessurize HOT coolant system to 15 psi using a hand pump Observe throttle body heater pipes at connection to throttle body for any signs of leakage Repair any coolant leakage observed here or elsewhere within the engine compartment NOTE 3 4 STEP 2 IS AN INSPECTION ITEM 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 T 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 ZONE CONTACT PERSON WITH SERVICE RESPONSIBILITY INSPECTION Conduct general inspection of vehicle for any other potential fire related issues specifically Rocker cover leakage from either gasket surface or PCV valve grommet leakage should be repaired if significant SEEPAGE IS NOT SIGNIFICANT Improper wiring harness coolant hose or fuel line routings which are resulting in chafing of a serious nature should be rerouted
16. tain all information required and should list the proper labor operation as outlined REIMBURSEMENTS Claims for customer reimbursements on previously paid repairs related to ONLY Exhaust Manifold and Exhaust Manifold Fastener Repairs are to be submitted in the following manner Use the special Owner Reimbursement labor operation listed under the Claim Information Section of this bulletin Reimbursement amounts of 150 00 or less can be processed by the dealer If the amount exceeds 150 00 an Owner Reimbursement Form 7201 039 Rev 6 88 must be forwarded to and processed by the Zone Office RECORDING COMPLETION Repairs submitted for vehicles not involved in this campaign will not be paid Campaign completion will be recorded from 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 Pontiac bulletins are intended for use by professional technicians NOT a do it yourselfer They are written to inform these 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 has that condition See your
17. tioned above the edge of the rocker cover Bracket should be removed cc Loosen shift cable bracket bolt already installed on manual trans mission equipped vehicles bolt supplied in kit for automatic trans mission equipped vehicles 10 PARTS IDENTIFICATION 6 CYL ITEM 9 1 GROMMET CRANKCASE VENT TUBE 1 1 TUBE ASA CRANKCASE VENT 12 1 CLAMP CRANKCASE VENT TUBE 1 DUCT ASM RIGHT REAR AIR INTAKE e 1 10 1 TUBE ASM CRANKCASE VENT 12 1 CLAMP CRANKCASE VENT TUBE f 13 RIGHT REAR AR INTAKE oe CAP NCLWOLE view 15 1 CLAMP ACLHOLE LH VALVE ROCKER COVER ILLUSTRATION J AIR INLET 87 88 dd Install new PCV grommet in the forward rocker cover new air intake duct w clamps and vent tube bracket assembly Orient grommet with flat side facing forward ILLUSTRATION I amp J Position tube bracket assembly under shift cable bracket bolt manual transmissions or install bolt supplied in kit automatic transmissions For 1987 88 vehicles install rubber cap with clamp on air cleaner housing Ginnnect engine strut and torque according to the applicable Fiero Service Manual procedure ffistall new oil filler cap on rear rocker cover gg Inspect battery cable and routing for any signs of chafing or wear Replace or reroute as necessary hh Connect battery and install engine compartment side outer grill ii Install J34730 1 Fuel Pressu
18. ve been sent to your dealer and parts are available The minimum labor time necessary to perform this service is approximately three and one half 3 1 2 hours Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle Your Pontiac dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible However 1f you take your vehicle to your dealer on the agreed service date and he does not remedy this condition on that date or within five days we recommend you contact the Pontiac Customer Assistance Center by calling 1 800 762 2737 After contacting your dealer and the Pontiac Customer Assistance Center you are still not satisfied that we have done our best to remedy this condition without charge within a reasonable time you may wish to write the Administrator National Highway Traffic Safety Administration 400 Seventh Street S W Washington DC 20590 or call 1 800 424 9393 Washington DC residents use 366 0123 The enclosed Campaign Owner Reply Card identifies your vehicle Presentation of this card to your dealer will assist in making the correction in the shortest possible time If you have sold or traded your vehicle please let us know by completing the postage paid Owner 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 c
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