SPECIAL POLICY: CRACKED EXHAUST MANIFOLD

Model and Year: 1985-86 CHEVROLET "J" CARS (CAVALIERS) W/2.0L ENGINE (CALIFORNIA ONLY)

TO: ALL CHEVROLET DEALERS

General Motors has determined that some 1985-86 Chevrolet Cavaliers built with 2.0L 4 cyl. LQ5 Engines (California Only) may experience a cracked exhaust manifold which could result in excessive engine noise.

VEHICLES INVOLVED

Involved are all 1989-86 Chevrolet Cavaliers built with 2.0L LQ5 engines (California Only) within the following VIN's:

MODEL/YEAR PLANT FROM THROUGH ---------- ----- ---- ------- J 1985 Janesville FJ100084 FJ287857

Leeds FK100007 FK148240

Lordstown F7102488 F7241597

J 1986 Janesville GJ100026 GJ309261

Leeds GK100225 GK173763

Lordstown G7106716 G7247334

Note: This policy applies to these vehicles produced with 2.0L RPO LQ54 cyl.engines (California Only), regardless of current state residence of the owner.

SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for those vehicles over 50,000 miles. A one time free inspection, and if necessary, free replacement of a cracked exhaust manifold (regardless of time/mileage) for three (3) months (90 days) from date of the owner letter is provided for by the "Special Policy". Correction will consist of the installation of a new exhaust manifold and exhaust pipe seal, at no charge to the owner.

This "Special Policy Adjustment Bulletin" should be filed in the three ring binder previously furnished to dealers by General Motors.

OWNER NOTIFICATION

Owners will be notified of this special policy on their vehicles by Chevrolet Motor Division (see copy of owner letter included with this bulletin).

REIMBURSEMENT

Customer claims for reimbursement on previously paid repairs to correct an exhaust manifold leak are to be submitted within 3 months (90 days) from the date of this letter according to the forms and instructions included in this bulletin (additional copies to be reproduced locally). Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity performing the repair.

PARTS INFORMATION

Parts are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered on a "C.I.O." order with no special instruction code, but on an advise code (2).

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ----------- ----------- ---------------- 14086036 Exhaust Manifold 1 14093542 Exhaust Manifold Seal 1

SERVICE PROCEDURE

INSPECTION

1. BLOCK THE WHEELS AND APPLY THE PARKING BRAKE. Lift the hood and listen for an audible exhaust noise while increasing the engine speed in park.

2. A check for a leaking exhaust seal (donut) should be performed prior to exhaust manifold replacement. If the seal leaks, replace it and rerun the inspection (WITH THE WHEELS BLOCKED AND PARKING BRAKE APPLIED) before exhaust manifold replacement.

MANIFOLD REPLACEMENT

IMPORTANT

The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the sensor.

Take care when handling the oxygen sensor. The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Also, avoid using cleaning solvents of any type. Do hot drop or roughly handle the sensor.

1. Disconnect battery ground cable from battery.

2. Disconnect Oxygen sensor electrical connector.

3. Carefully remove Oxygen sensor from exhaust manifold.

4. Remove engine oil dipstick.

5. Remove air cleaner hot air duct hose.

6. Remove the screw retaining the dipstick tube bracket (and A/C suction line bracket, if so equipped).

7. Loosen the generator support to generator bolt, remove the two generator bracket to generator bolts, being careful not to loosen the spacer used at the left generator to bracket bolt.

8. Remove the generator belt from the generator pulley, rotate the generator upward and install the left generator to bracket bolt loosely so that it acts as a stop against the bracket preventing the generator from rotating too far downward.

9. Raise the vehicle.

10. Disconnect the exhaust pipe from the exhaust manifold.

11. Lower the vehicle.

12. Remove exhaust manifold to cylinder head bolts, lift the exhaust manifold off the exhaust pipe flange and remove the exhaust manifold from the cylinder head.

13. Clean all mating surfaces, bolts and bolt holes.

14. Reverse the manifold removal procedure and torque the fasteners to the following specifications:

Exhaust manifold bolt: 46-60 Nm (34-44 Lb. Ft.) Generator Brkt. to Head: 40-60 Nm (29-44 Lb. Ft.) Generator Brace: 40-60 Nm (29-44 Lb. Ft.) Generator Pivot Bolt: 40-60 Nm (29-44 Lb. Ft.) Generator Adjustment Bolt: 20-27 Nm. (15-20 Lb. Ft.)

IMPORTANT

New or service sensors will already have a special anti-seize compound on the threads. If a sensor is removed from an engine, and if it is reinstalled, the threads must have anti-seize compound applied before reinstallation.

15. Coat threads of oxygen sensor with anti-seize compound P/N 5613695 or equivalent if necessary.

16. Reinstall sensor in manifold, torque to 41 Nm. (30 Lb. Ft.).

17. Reconnect sensor electrical connector.

18. Connect battery ground cable to the battery.

CLAIM INFORMATION

Submit a Claim with the information indicated below for those vehicles beyond 5 years/ 50,000 miles; use the applicable Warranty labor operation number for those vehicles within 5 years/50,000 miles:

FAILED PARTS CC/FC LABOR LAB REPAIR PERFORMED PC PART NO. ALLOW OP HRS ---------------- -- -------- ------- ----- ----- ---- Inspect for leak - - - * SG-95 T1518 0.2

Install New 1 14086036 * SG-95 T1519 1.3 Manifold

Inspect for leak, 1 14093542 * SG-95 T1527 0.3 replace seal only

* The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.

Refer to the Chevrolet Claims Processing Manual for details on Claim Submission.

August 11, 1989

Dear Chevrolet Owner:

As the owner of a 1985-86 Chevrolet Cavalier equipped with a 2.0L engine, your continued satisfaction with our product is of utmost concern to us. Your vehicle was provided with a new vehicle warranty as well as an emission warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you experience problems with your vehicle.

This letter is intended to make you aware that some vehicles have experienced a cracked exhaust manifold. The cost to repair this condition may be as much as $200.00. The affected part is listed in the California Emission Warranty Parts List and is covered under the California emissions warranty for 5 years/50,000 miles whichever occurs first.

Leakage may be detected by listening for excessive engine noise during acceleration. You need to return to your servicing Chevrolet dealer for a free inspection only if you notice this problem. If the above mentioned condition exists and your vehicle is within the 5 year/50,000 mile California Emission Warranty, it will be repaired free of charge. If you previously paid for this repair, you should contact your Chevrolet Dealer within 3 months (90 days) from the date of this letter to request reimbursement. Vehicles beyond the 5 year/50,000 mile period will be inspected and repaired free of charge for a period of 3 months (90 days) from the date of this letter.

If the above condition exists, please contact your Chevrolet dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle. The labor time necessary to perform this service (inspection/correction) is approximately 1.3 hours.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist in making the necessary (inspection/correction) in the shortest possible time.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor Division GENERAL MOTORS CORPORATION

INSTRUCTIONS

1 R.O.# & DATE The dealership should enter the repair order number and date of the owner's or dealer's paid receipt or invoice.

2 REQUEST DATE (MONTH. DAY) Date owner or dealer requested reimbursement.

3 VEHICLE IDENTIFICATION NUMBER VIN involved.

4 MILEAGE Enter mileage at time of transaction. (if not available, enter "O".)

5 CC/FC Code is preprinted on form.

6 LABOR OPERATION Labor Operation is preprinted on form.

7&8 SUBLET DMN & Enter total amount of reimbursement. (Do not enter parts or LINE TOTAL labor hours on claim.)

9 AUTH CODE If the amount of reimbursement approved is $300 or less, no authorization is needed. If the amount exceeds $300, advise customer to contact Chevrolet Customer Assistance at 1-800-222-1020.

10 REQUESTED Dealer Service Manager enter amounts determined from owner REIMBURSEMENT supplied invoices or paid receipts, which are covered.

11 APPROVED AMOUNT Dealer Service Manager to determine based on reimbursement policy of this bulletin. If the total amount exceeds $300, contact Chevrolet Branch Customer Assistance Representative for instructions.

12 740 STAMP See Item #11 to determine need for authorization.

13 DEALER REFERENCE INFORMATION A Enter Document Number and Line Number on which claim was submitted.

B Enter Claim Memo Number and Date when claim is credited.

C Enter number of dealer check to owner, if applicable. Date check was written, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.

14 OWNER INFORMATION Must include telephone number.

15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's signature and social security number. To be completed by Service Manager.

16 EXPLAIN Should the dealer Service determine, after review of owners invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet on file.

17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be atttached to the dealer's file copy of the request and retained for 24 months from date of credit.

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.