Product Safety - Engine Compartment Fire

Due to parts availability, recall customer letters will be mailed in two phases. 1997-2000 model year customer letters will be mailed one week after bulletin launch. Dealers will be notified when 2001-03 model year customer letters are mailed.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 1997-03 model year Buick Regal GS and Pontiac Grand Prix GTP model vehicles, equipped with a 3.8L V6 Supercharged (RPO L67 - VIN 1) engine. Some of these vehicles have a condition in which drops of engine oil may be deposited on the exhaust manifold through hard braking. If this condition occurs, and if a hot surface ignition source were present, an engine compartment fire could occur.

Dealers are to replace the left rocker cover gasket/grommets and the 1-3-5 spark plug wire retainers.

Involved are certain 1997-03 model year Buick Regal GS and Pontiac Grand Prix GTP model vehicles, equipped with a 3.8L V6 Supercharged (RPO L67 - VIN 1) engine and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

-- US GM dealers - GM DealerWorld Recall Information

-- Canadian GM dealers - GMinfoNet Recall Reports

-- Export dealers - sent directly to dealers

The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

Important: The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.

1997 - 2003 3.8L L67 Left Valve Cover Gasket Replacement Along with Removal and Installation of Retainer for 1-3-5 Spark Plug Wires

Important: Clean the area around the tube/oil fill cap before removing the tube/oil fill cap in order to prevent contaminants from falling into the valve cover opening.

1. Remove the fuel injector sight shield (1).

1.1.	Twist counterclockwise to unlock the tube/oil fill cap from the valve cover.

1.2.	Remove the upper intake manifold cover nut holding the fuel injector sight shield to the fuel injector rail brace stud.

1.3.	Lift the fuel injector sight shield up at the front and slide the tab out of the engine bracket.

1.4.	Re-install the tube/oil fill cap in the valve cover to prevent engine oil contamination.




2. Remove the left engine mount strut (2).

2.1.	Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the engine (1).

2.2.	Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).

2.3.	Remove the engine mount strut (2).




3. Remove the 1-3-5 spark plug plastic retaining channel (cover) clip/bracket from the engine and discard (1).

Important: It is not necessary to remove the spark plug wires from the spark plugs.

4. Remove all six spark plug wires from the ignition coils only. Set the spark plug wires aside.



5. Remove the supercharger drive belt (1).

Lift or rotate the supercharger drive belt tensioner using a 15 mm box end wrench on the pulley nut and remove the belt.




6. Remove the supercharger drive belt tensioner (1) and idler pulley (2).

6.1.	Remove the supercharger drive belt tensioner nut and remove belt tensioner (1) from the engine.

6.2.	Remove the idler pulley bolt (2).

6.3.	Remove the drive belt idler pulley (2) from the engine.





Important: It is not necessary to remove the ignition coils/module or the 14-way connector (1) from the left engine mount strut bracket.

7. Remove the left engine mount strut bracket as assembly (1).

7.1.	Remove the left engine mount strut bracket assembly nuts.

7.2.	Remove the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.

7.3.	Remove the left engine mount strut bracket assembly (1) from the cylinder head and set aside.

Danger

8. Do not use a brake cleaner, or equivalent to remove the oil residue from the exhaust manifold; doing so may cause an engine fire.

Notice: Before the removal of the left or front engine valve cover, use an engine degreaser or equivalent in order to remove the oil residue from the exhaust manifold and the oil and dirt residue from the cylinder head and engine block. It may be necessary to use a brush or scraper.




9. Remove the left or front engine valve cover (1).

8.1.	Remove the valve cover bolts.

Important: If the valve rocker arm cover (1) adheres to the cylinder head, remove the valve cover by bumping the end of the valve cover with palm of hand or with a soft rubber mallet.

8.2.	Remove the valve cover from the engine cylinder head.

8.3.	Remove the valve cover gasket.

8.4.	Clean the sealing surface on the cylinder head and the valve cover with a engine degreaser or equivalent.

8.5.	Clean the valve cover bolts of all dirt, grime or thread locking adhesive.




10. Install a new left or front valve cover gasket (1) , P/N 24503937, and make sure that valve cover gasket is seated properly in the valve cover groove.

9.1.	Install the valve cover and gasket (1) to the cylinder head.

9.2.	Install the six valve cover bolts and six new grommets.

-	Replace with new grommets, P/N 25534749 (package - qty.5).

-	Two packages will be needed. Save the other four grommets for future repairs.

9.3.	Apply medium strength thread lock compound (blue), GM P/N 12345382 (in Canada use P/N 10953489) or equivalent, to the six valve cover bolt threads.

Tighten
Tighten the valve cover bolts to 10 N·m (89 lb in).




11. Install the left engine mount strut bracket assembly to the cylinder head (1).

10.1.

Install the left engine mount strut bracket nuts and stud.

10.2.

Install the stud holding the electronic ignition control module ground and left engine mount strut bracket assembly to the cylinder head.

Tighten
Tighten the left engine mount strut bracket nuts and stud to 50 N·m (37 lb ft).

12. Install all six spark plug wires to the ignition coils.

7mm Four-Wire Retainer P/N 88891792




13. Install a 7 mm four-wire retainer, P/N 88891792 (1) (Qty 5/pack) to spark plug wire number 4, then to spark plug wires 1, 3 and 5. If not available, use 8 mm spark plug four-wire retainer (1), P/N 14066248 (Qty 10/pack), or equivalent 7mm aftermarket spark plug wire retainer. Save the other 7 mm or 8 mm spark plug four-wire retainers for future repairs.

7mm Two-Wire Retainer P/N 12132229





12.2.

Install a 7 mm two-wire retainer, P/N 12132229 (Qty 10/pack) to spark plug wires 3 and 5 only (1). Save the other 7mm spark plug two-wire retainers for future repairs.





12.3.

Install the 7 mm four-wire retainer, P/N 88891792 to spark plug wire number 4 (1) then to spark plug wires 1, 3 and 5 (2). Make sure that spark plug wires 2, 4 and 6 are secured to the original retainers and under the left engine mount strut bracket.

12.4.

Install the 7 mm two-wire spark plug retainer, P/N 12132229 (Qty 10) to spark plug wires 3 and 5 only (3). Make sure the spark plug retainer (3) is approximately 50 mm (2 in) from the oil level indicator.




14. First install the supercharger drive belt idler pulley and bolt (2). Then install the supercharger drive belt tensioner and nut (1).

Tighten
Tighten both the supercharger drive belt idler pulley bolt and supercharger drive belt tensioner nut to 50 N·m (37 lb ft).




15. Install the supercharger drive belt (1).

Lift or rotate the drive belt tensioner using a 15 mm box end wrench on the pulley nut and install the supercharger drive belt.




16. Install left engine mount strut bracket (2).

14.1.

Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the upper radiator support (1).

Tighten
Tighten the engine mount strut bolt to 48 N·m (35 lb ft).

Important: If equipped, the P-clip on the engine wiring harness must be vertical to the left engine mount strut bracket when installed.

14.2.

Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the engine (1).

Tighten
Tighten the engine mount strut bolt to 48 N·m (35 lb ft).




17. Install fuel injector sight shield (1).

15.1.

Remove by twisting counterclockwise to unlock the tube/oil fill cap from the left valve cover.

15.2.

Insert the tab of the fuel injector sight shield under the engine bracket.

15.3.

Place the hole of the fuel injector sight shield onto the oil fill neck of the left valve cover.

Important: Make sure the newly installed spark plug retainers are not in contact with the fuel injector sight shield or the exhaust manifold.





Important: Make sure the new 7 mm two-wire retainer (2) is approximately 50 mm (2 in) from the oil level indicator.

Important: Make sure the newly installed 7 mm four-wire (1) and 7 mm two-wire (2) spark plug retainers are not in contact with the fuel injector sight shield, engine mount strut bracket or the exhaust manifold.

15.4.

Install the tube/oil fill cap into the left valve cover and twist clockwise in order to lock the detent on the tube into the notch in the valve cover.

Tighten
Tighten the fuel injector sight shield cover nut to 3 N·m (27 lb in).

18. Inspect for the proper oil level.
19. Inspect for any oil leaks.

All customer requests for reimbursement of previously paid repairs for the recall condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: (For GM US Only) Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs for the recall condition are to be submitted to the dealer by April 30, 2009.

All reasonable customer paid receipts should be considered for reimbursement. The amount to be reimbursed will be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

When a customer requests reimbursement, they must provide the following:

Claims for customer reimbursement on previously paid repairs are to be submitted as required by WINS.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement verification.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to 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 customer 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 remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 1997-03 model year Buick Regal and Pontiac Grand Prix model vehicles, equipped with a 3.8L V6 Supercharged engine. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

We recently sent you a letter about this issue in March.

Important: 

Why is your vehicle being recalled?

These vehicles have higher front rocker cover gasket temperatures, creating the potential for earlier degradation of the front rocker cover gasket and eventual oil seepage. Certain underhood fires may be caused by drops of engine oil, from seepage or spillage, being deposited on the exhaust manifold through hard braking. If the manifold is hot enough and the oil runs below the heat shield, it may ignite into a small flame and, in some instances, the fire may spread to the plastic spark plug wire channel and beyond. If this occurs, there could be a fire in your vehicle and nearby property.

What will we do?

Your GM dealer will install a new front rocker cover gasket with an improved design over the original gasket and replace the spark plug wire channel with new retainers. This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 55 minutes.

If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner’s Manual and your dealer for details on courtesy transportation.

What should you do?

You should contact your GM dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

There are two very important precautions you should take before your vehicle is serviced:

For your continued satisfaction with your vehicle, you should know:

Did you already pay for this repair?

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the recall condition.

Do you have questions?

If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall.

If after contacting your dealer and the Customer Assistance Center, you are still not satisfied 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, 1200 New Jersey Avenue, SE, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

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