Formal Engine Exchange Program for 1999 Model Year

This bulletin is being revised to remove the Cutlass and to update several Serviceable Components. Please discard Corporate Bulletin Number 57-61-31F (Section 6 -- Engine).

Because product teams continually seek valuable information for product engineering improvements, a formal engine exchange program will, once again, be administered by GM Powertrain during the 1999 model year. The duration of the formal program, however, is shortened to six months. Routinely, engineering learnings from an exchange program are fairly complete after the first six months of field experience. Conditions encountered after that are generally repeats of previously found concerns. Also, established criteria for inclusion in the formal engine exchange program are being strictly enforced for the 1999 model year.

In the interest of consistency and better communication, this single bulletin serves as the overall cancellation of the previous (1998) model year formal engine exchange program and announcement for the 1999 model year engine exchange program inclusion. The engines for applications (models) identified above will be exchanged during the 1999 model year program which is effective beginning September 1, 1998 and ends February 28, 1999.

As in the past engine exchange programs, you must call your technical assistance groups in order to request an exchange engine.

If any internal components of a 1999 model year engine require replacement, the engine must be exchanged. Components of a 1999 engine which MAY be serviced without exchange or removed for diagnosis are identified by an "x" in the following table in each engine type column.

Engine components on the "serviceable component list" above must be serviced according to the repair procedures in the applicable vehicle service information publication (manual). Engine components NOT included in the above list will require an engine exchange.

Contact Technical Assistance in order to establish a case reference number and to make arrangements for shipping an exchange unit to your dealership. In order to increase effectiveness of the program, the unit removed from the vehicle must be returned immediately (no later than 7 days after the receipt of the replacement unit).

Important: Failure to return the concerned engine will result in the dealership being billed the net cost of the exchanged engine.

The removed unit must be returned complete in the exchange engine shipping container. For effective engineering analysis, please do not remove any components. Engine dress on the removed unit must remain the same as the replacement engine (e.g., exhaust manifolds, throttle body, etc.). Dealerships returning engines that have been partially disassembled will be judged as violating this procedure and will be billed for all materials furnished.

The exchange unit will be shipped with a quantity of oil. Check the oil level before starting the engine.

The exchange unit will also include return shipping instructions, including a return shipping label (freight collect at destination) and a partially completed Bill of Lading.

Important: Drain all fluids from the removed engine and install any plugs taken off the exchange engine.

Remove the engine assembly as outlined in the applicable service manual. Remove any plastic shipping plugs and covers from the exchange unit and install them on the removed unit.

If the concerned engine leaks, mark the area directly on the engine. Write the Technical Assistance Case reference number on the repair order form.

Place the removed engine into the original shipping container. Place a copy of the repair order and the completed identification card in an envelope and attach the envelope to the engine being returned.

Important: CF Logistics is coordinating all exchange engine returns. Their hours of operation are 7:00 a.m. to 6:00 p.m. Central Time, Monday through Friday. You may contact them at 1-800-260-7834 to arrange for exchange engine core pickup. Use ground freight only!

Remove the original shipping tap and attach the return shipping label to the container. The Bill of Lading and Custom Papers (Canada only) provided with the exchange engine are the only documents required to return the removed engine.

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 copies to the carrier. Your copy of the Bill of Lading, signed by the carrier, is proof of returning the engine.

The removed engine is to be shipped by Truck Freight Collect to the engine plant of origin (refer to the detailed instructions provided in the information packet accompanying the exchange engine). Please identify the dealer address (i.e., the return address) and Technical Assistance case reference number on the outside of the crate.

If the envelope containing the shipping information becomes lost, please contact your technical assistance line for shipping instructions or the appropriate engine plant at the numbers listed below.

Use the following information for claim submission:

Important: Applicable miscellaneous items such as engine oil and coolant should be added to the part allowance amount and included in the Net Amount (DMN) column of the warranty claim.

Your cooperation is greatly appreciated. Prompt return of your concerned unit will increase the effectiveness of this program. If you have any questions regarding the exchange program administrative procedures, please contact technical assistance.