CAMPAIGN: ENG. MAIN BEARING CAP BOLTS MAY BREAK

MODELS AFFECTED: 1983 Skyhawks Equipped With 1.8L Engine (VIN Code 0)

General Motors has determined that some 1983 Skyhawk models equipped with 1.8 liter Electronic Fuel Injectior/Overhead Cam Engines may have been assembled with incorrect engine main bearing cap bolts. In some cases, the main bearing cep bolts could break. This could cause extensive damage to the engine crankshaft.

To prevent this from occurring, dealers are to inspect vehicles for specific engine identification and, if necessary, replace the engine main bearing cap bolts.

VEHICLES INVOLVED

Involved are some 1983 Skyhawks equipped with 1.8L Overhead Cam EFI 4 cylinder engine (UPC Code LHB) built within the following breakpoints:

PLANT BEGINNING VIN UP TO & INCLUDING

Leeds DK4?7934 DK428899

DEALER CAMPAIGN RESPONSIBILITY

Dealers are to inspect the vehicle for specific engine serial number and identification and, if necessary, replace the engine main bearing cap bolts. 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 in your dealership for 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.

DEALER MATERIAL

If your dealership has vehicles involved in this campaign you will receive the following:

List of vehicles involved in this campaign shipped to your dealerships.

A campaign identification label for each vehicle.

OWNER NOTIFICATION

Owners of vehicles involved in this campaign will be notified by Buick Motor Division (see copy of owner letter included with this bulletin). Involved vehicles 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 the 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 computer 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 purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing for the follow-up necessary to complete this campaign.

Owners of vehicles recently sold from your new vehicle inventory are to be contacted by the dealer, and arrangements made to make the recuired modification according to instructions contained in this bulletin.

TRANSFER OF VEHICLE

If a vehicle has been transferred or sold to another location, please forward Campaign Identification Label and vehicle infomation for this vehicle to your Buick Zone Office for handling with the proper dealer.

CHANGE OF OWNER INFORMATION

Dealers are to use the Dealer Commnication System (D.C.S.) to provide Buick Motor Division with subsequent Buick Owner Information. By reporting a change of owner name or address of a vehicle in Campaign status over the D.C.S., the need to send in an S-866 Form for that vehicle is eliminated. Teminal input instructions are covered in the D.C.S. Manual under Section 9, Page 9-J01A and B.

PARTS INFORMATION

Campaign requirements of part number 11072446 (bearing bolts - 10 per vehicle) are to be obtained by the dealer from WDDGM.

Very few vehicles will need replacement of engine main bearing cap bolts. So that parts will be obtained as soon as possible, they should be ordered from GM Parts (WDDGM) on a C.I.O. order with no special instruction code, but order on an advise code (2).

TECHNICAL PROCEDURE

1. Open hood.

2. Inspect engine identification paper tag located on engine timing cover.If the engine identification tag is missing, the engine identification number is engraved on a horizontal bo ss located on the cylinder block, directly underneath the number 4 spark plug.

3. If engine serial number is between 77117 and 83420, proceed to Step 5. Replacement of ten (10) engine main bearing cap bolts is needed.

4. If engine serial number is not between 77117 and 83420, vehicle passes inspection and no repair is needed. Proceed to Step 19.

Main Bearing Bolt Replacement

5. Hoist vehicle. If a twin post hoist is being used, position Jackstand at vehicle Jacking points and lower post.

6. Drain oil from crankcase.

7. Remove exhaust pipe from exhaust manifold.

8. If equipped with air conditioning, remove lower air conditioning strut bracket.

9. Remove flywheel dust shield.

10. Remove oll pan. Slide the oil pan forward, then downward to clear the oil pump pickup tube.

11. Inspect for broken bolts, and then replace the ten (10) main bearing cap bolts. Torque new main bearing cap bolts to 77 N.m (57 lb. ft.).

a. If any broken bolts are found in the #1, #2, #3 or #4 main bearing positions, remove the main bearing cap and inspect the bearing.

b. If any main bearings appear to be damaged or have spun, replace the bearing.

c. If a broken bolt is found in the #5 main bearing position; visually inspect the cap to determine whether the bearing has moved. If the bearing cap has not moved, replace the bearing cap bolts only.

d. If removal of #5 main bearing cap is necessary, the area requiring sealer must be cleaned and resealed using dealer kit GM #3997597. Refer to illustration. Be sure the rear main oil seal is properly aligned.

e. If the engine block has been damaged as a result of a spun bearing, replace the engine block.

12. Install oll pan and new oil pan gasket. Apply RTV sealer to oil pan gasket at the oil pump mating surface.

13. If equipped with air conditioning install air conditioning strut bracket.

14. Install flywheel dust shield.

15. Install exhaust pipe to exhaust manifold.

16. Lower vehicle.

17. Refill crankcase with oil.

18. Start engine and check for oil leaks.

19. Each vehicle modified in accordance with the instructions outlined in the Technical Procedure will require a campaign identification label. Each label provides a space to include the campaign number, the five-digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label on the fan shroud where it is readily visible.

DISPOSITION OF PARTS

Replaced parts must be held for disposition by Buick Contact Personnel. Parts must have a claim tag attached, showing the repair order and the VIN of the vehicle from which they were removed.

WARRANTY INFORMATION

Dealers are to submit each campaigned vehicle as a separate case on the one-line Warranty Document Form S-764. Dealers submitting warranty claims by teletype terminal are to transmitt Campaign completions as a separate case also. List only the one applicable labor operation.

LABOR AND PARTS CREDIT

Sublet Parts Failure Labor Labor Other Dealer Operation Allow. Code Op.No. Hours Hours Mtl. Twg.

*Inspect Engine Number 96 V1580 .2 *.1 *Inspect Engine Number and Replace 10 Bolts - With Air Conditioning 96 V1581 1.6 *.1 *** 5.85 Without Air Conditioning 96 V1582 1.4 *.1 *** 5.85 *Inspect Engine Number, Replace 10 Bolts and One Main Bearing With Air Conditioning 96 V1583 1.8 *.1 *** 5.85 Without Air Conditionina 96 V1584 1.6 *.1 *** 5.85

* .1 hour for administration.

** List current dealer price plus 30% of ten (10) main bearing cap bolts number 11072446, oil pan gasket number 90106425 and for the main bearing(s) replaced when using labor operation V1583 or V1584.

*** Dealer material is for 3 quarts of engine oil ($4.50) plus 30% ($1.35).

Add .2 hour to labor operation V1583 or V1584 for each additional main bearing replaced.

To assure accurate records of all transactions on this Campaign, it is recomended that Campaign repairs for each vehicle be listed on a separate repair order. Other repairs performed to the vehicle may be listed on the same repair order, and warranty cases other than Campaigns may be listed on the same warranty document.

Warranty documents on this Campaign are not to be sent to the Zone Office. Send directly to Buick, Flint, as is done with normal submissions o warranty documents.

Zone authorization is not required.

Dear Buick Owner,

General Motors has determined that some 1983 Buick Skyhawks equipped with 1.8 liter Electronic Fuel Injection/Overhead Cam Engines may have been assembled with incorrect engine main bearing cap bolts. In some cases, the main bearing cap bolts could break. This could cause extensive damage to the engine crankshaft.

To prevent this from occurring, your Buick dealer will inspect your vehicle for specific engine identification. If necessary, they will replace the engine main bearing cap bolts. This service will be performed at no charge to you.

Instructions for making this correction have been sent to your Buick dealer. Please contact your dealer to arrange a service date. The labor time necessary to perfom the inspection is approximately ten minutes. If the main bearing cap bolts must be replaced, the labor time will be approximately one and one half additional hours. Please allow additional time for the dealer to process your vehicle.

The enclosed owner reply card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary correction to your vehicle 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 continued satisfaction with our products.

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.