ENGINE EXCHANGE PROGRAM 2.3L SINGLE OVERHEAD CAM-SER. INFO
SUBJECT: ENGINE EXCHANGE PROGRAM FOR 1992 "N" CAR W/2.3 LITRE (L40) SINGLE OVERHEAD CAM (SOHC) ENGINE - SERVICE INFORMATION
VEHICLES AFFECTED: 1992 "N" CAR
THIS BULLETIN IS BEING REVISED TO MAKE THE FOLLOWING CORRECTIONS UNDER:
B. EXCHANGE PROCEDURE ------------------- Revised second sentence, paragraph 3. Deleted second sentence, paragraph 8.
Bulletin Covers:
An exchange program now in effect to gain needed product feedback on the 1992 model year 2.3L (L40) Quad 4 OHC engine used with N-car applications. The exchange program will continue through the end of the 1992 model year and is administered by the Technical Assistance Centre (TAC).
Service Information:
All requirements qualifying for engine exchange, warranty claims, processing procedures and shipping instructions are explained below. Your cooperation in following these procedures will greatly improve the effectiveness of the program. File this information in the "Special Exchange Policy Procedures" manual.
A. ENGTNE EXCHANGE GUIDELINES: -------------------------- Conditions which would normally require partial engine replacement, a block or block components are indicated by the following symptoms:
1. Knock noises deep in the engine (i.e., crankshaft or rod bearing, piston or piston pin).
2. Seized engine (i.e., engine is locked and will not turn over with spark plug removed).
3. Low or no cylinder compression.
4. Excessive oil consumption.
5. Hydraulic lock.
6. Crack or porosity in cylinder block.
7. Coolant in the oil, and/or air bubbles in surge tank.
8. For a limited time (until approximately March 1992) the following conditions also qualify:
a. Conditions of excessive chain rattle noticed inside the car with engine running at idle speed.
b. Valve train noise conditions which would require removing the cylinder head.
COMPLETE ENGINES ARE REQUIRED FOR EXCHANGE!!!
B. EXCHANGE PROCEDURE: ------------------ Once the above preliminary diagnosis is made and an exchange unit is deemed necessary, call your Technical Assistance (TAC) Chassis Group
- TAC will require the VIN and engine serial number. (Engine serial number can be read from the timing chain cover. It begins with the letter "D" and is followed by a six digit number.)
- TAC will arrange to ship a replacement engine within 48 hours. The replacement engine will be complete except for flywheel, intake and exhaust manifolds, IDI assembly, fuel rail, injectors and throttle body, starter, accessory drive components and brackets.
- A TAC case number will be provided for each engine exchange. This number must be recorded on the identification card supplied with the replacement engine and must be affixed to the engine being returned. The identification card must be filled out completely.
- To avoid a chargeback, the exchange unit must be returned to Lansing within 10 days in the original shipping crate. Failure to return the concerned unit will result in the DEALERSHIP being billed the value of an exchange unit.
- The exchange unit must be complete as removed from the vehicle. Dealerships returning incomplete units risk being billed for missing materials.
All procedural steps must be followed to ensure the dealership is not billed for an engine.
The removed unit must be returned complete as removed from the vehicle in the container provided, without examination of the unit other than as described above. Dealerships returning units even partially disassembled will be judged as violating this procedure and as such will be subject to being billed for all materials furnished.
The exchange unit will be shipped with minimum quantity of oil; add oil per specifications.
Attached to the exchange unit will be a return shipping label (freight is prepaid).
D. PREPARATION FOR SHIPPING: ------------------------ Visually check all fluid levels to assure they are within the normal operating range. If not, drain and measure the oil and coolant from the concerned unit. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG.
Remove engine assembly as outlined in the 1992 Service Manuals.
Remove all plastic shipping plugs and covers from the exchange unit and install them on the removed unit.
If engine leaks, mark leak area on engine. Write the TAC reference number on the repair order form.
Place the removed unit into the original shipping container. Include a copy of repair order in original envelope and attach to original engine.
E. SHIPPING INSTRUCTIONS: --------------------- Place the shipping label over the original container shipping label. The Bill of Lading and Customs Papers (when necessary) provided with the exchange engine are the only documents required to return ship the removed engine.
NOTE: The same carrier, whose name is indicated on the Bill of Lading, should be used for the return engine shipment.
All required data on the Bill of Lading will be complete, except for the date and carrier signature. After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your repair order and provide the other two copies to the carrier. Your copy of the Bill of Lading, signed by the carrier, is your proof of returning the engine.
The removed engine is to be shipped by Truck Freight Collect to:
GM Powertrain Delta Engine Plant, Store #9 2901 South Canal Road Lansing, MI 48917
Attn: Part Return
To increase the effectiveness of the program, the removed unit should be returned IMMEDIATELY. Failure to return the removed unit will result in the dealership being billed $ 2950.00 for the unit furnished, plus an administration charge.
F. WARRANTY CLAIMS PROCESSING PROCEDURE: ------------------------------------ Upon completion of the repair, a warranty claim is to be submitted to the Marketing Division.
Labour Operation Part Labour Other Number Description Allowance Hours Hours --------- ----------- --------- ----- ------ J1880 Replace Engine Assembly $ 475.00 (with manual transmission) 6.3 hrs 0.2 hr (with automatic transmission) 6.2 hrs 0.2 hr
Add:
(with air conditioning) 0.5 hr (with cruise) 0.1 hr (with locking wheel covers) 0.1 hr
* Administrative Allowance.
NOTE: Applicable miscellaneous items, such as engine oil and engine coolant, should be added to the above Part Allowance amount and included in the Net Amount (DMN) column of the claim.
YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS CONCERNING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT THE TECHNICAL ASSISTANCE CHASSIS GROUP.
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.
