EI06005 - 1.6L L91 Timing Belt Inspection, Maintenance, Worn, Wear

This bulletin is being updated to add models and model years and clarify the belt maintenance schedule and handling of belt breakage. Please discard Corporate Bulletin Number 06-06-01-021A (Section 06 -- Engine).

The current maintenance schedule requires timing belt replacement at 100,000 km / 60,000 mi. Information provided by the field provided no reason to replace the belt early. However, extending the belt usage past the recommended 100,000 km / 60,000 mi replacement interval could result in a non-warranty belt failure.

Important:  Belt replacement at every 100,000 km / 60,000 mi interval is a customer paid maintenance requirement for the L91 engine. Inspection of the timing belt prior to the 100,000 km / 60,000 mi is no longer required.

Engine damage resulting from timing belt failure prior to the required replacement interval (at 100,000 km / 60,000 mi) should be submitted as a Field Product Report (U.S. dealers) or a Product Information Report (Canadian dealers) and considered under warranty. Parts should be retained as usual; expecting a potential Warranty Parts Center (WPC) request.

Belt wear discovered prior to the replacement interval and NOT attributed to the failures list below should be submitted as a Field Product Report and considered under warranty. Parts should be retained as usual; expect a potential Warranty Parts Center (WPC) request.

Consequential belt failure may occur due to any of the following:

Recommended Instructions If Timing Belt Breakage Occurs:

If timing belt breakage is encountered, inspect the engine for consequential valve, valve guide, and cylinder head damage, and repair as necessary. Typically, the engine pistons, rods, bearings and crankshaft will not be affected by impact with the valves, however, the piston top surface should be inspected carefully to confirm that no significant damage is present. Valve impact marks or indentations in the piston tops do not require replacement action unless there is evidence of piston cracking.

1. If timing belt damage or breakage occurs PRIOR to the required 100,000 km / 60,000 mile timing belt replacement interval, the engine should be repaired and the belt replaced under the 5 year / 60,000 mile (in Canada, 5/100) warranty. Engine damage induced by timing belt failure should not be denied based solely on the customer's inability to produce proof of a previous timing belt inspection.
2. If timing belt damage or breakage occurs AFTER the required 100,000 km / 60,000 mi timing belt replacement interval and the timing belt had NOT BEEN PREVIOUSLY REPLACED within the required 100,000 km / 60,000 mile timing belt replacement interval, the engine repair should be at the expense of the customer because the engine is outside the warranty window and the recommended belt replacement interval was ignored.
3. Customers who have previously incurred out of pocket repair costs associated with timing belt failures prior to 100,000 km / 60,000 miles, may contact the Customer Assistance Center (CAC) to petition repair reimbursement. CAC will require documentation of the repair and mileage.
4. Dealer service departments should advise customers that 100,000 km / 60,000 mile belt replacement is required maintenance and GM may deny warranty coverage if the belt is not replaced within the required maintenance period.

Important:  Timing belt failures prior to 100,000 km (60,000 mi) are covered under the Powertrain Component warranty.

For vehicles repaired under warranty, use: