SPECIAL POLICY:(CANADA ONLY) COOLANT LOSS, VISIBLE, COOLANT. Chevrolet Cavalier 1993

SPECIAL POLICY - CANADA ONLY

SUBJECT: COOLANT LOSS, VISIBLE COOLANT LEAKAGE, LOW COOLANT LAMP, ON, OR COOLANT ODOUR, CAUSED BY HEAD GASKET FAILURE

MODELS: 1992,1993, AND 1994 CHEVROLET CAVALIER WITH 2.2L ENGINE (VIN 4 - RPO LN2)

THIS BULLETIN CANCELS AND REPLACES SPECIAL POLICY BULLETIN 6SOI ISSUED MARCH 1996. THE INVOLVED POPULATION HAS BEEN EXPANDED TO INCLUDE THE 1994 MODEL YEAR. ALL COPIES OF 6SO1 SHOULD BE DESTROYED.

CONDITION

General Motors of Canada Limited has determined that certain 1992, 1993 and 1994 Chevrolet Cavalier model vehicles equipped with 2.2 litre engines (VIN CODE 4 - RPO LN2) may develop a failure of the cylinder head gasket leading to external coolant leaks from the cylinder head gasket to engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odour of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

To correct this condition, a new cylinder head gasket will be installed.

SPECIAL POLICY ADJUSTMENT:

This special policy covers the condition described above for a period of seven years or 160,000 kilometres, whichever comes first, from the date the vehicle was originally placed in service, regardless of ownership.

The repairs will be made at no charge to the owner. This special policy applies ONLY to repairs requiring cylinder head gasket replacement as a result of cylinder head gasket failure that results in an engine coolant leak. It does not cover engine drainage from continuing to operate the engine in an overheated condition after loss of coolant.

VEHICLES INVOLVED

Involved are some 1992, 1993 and 1994 Chevrolet Cavalier model vehicles built within the following VIN breakpoints:

YEAR DIVISION MODEL PLANT PLANT CODE FROM THROUGH

1992 Chevrolet Cavalier Ramos S S000014 S847446 1992 Chevrolet Cavalier Lordstown 7 7100380 7325877 1993 Chevrolet Cavalier Ramos S S000009 S842882 1993 Chevrolet Cavalier Lordstown 7 7100027 7352035 1994 Chevrolet Cavalier Ramos S S800011 S869638 1994 Chevrolet Cavalier Lordstown 7 7100025 7369874

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements.

Quantity/ Part Number Description Vehicle

24576546 Cylinder Head Gasket 1 3634621 Cooling System Sealer 2 Pellets per Vehicle (Package of 6 Pellets) 993194 Bulk Engine Oil (5W30) 4.02 Litres (4.25 Quarts) 25010792 Engine Oil Filter (PF47) 1 10070107 Valve, Coolant Air Bleed 1* 993089 Bulk Engine Coolant 4.73 Litres (5 Quarts)

* Valve is only necessary if inspection confirms that there is no valve already in place on 1994 vehicles.

CUSTOMER NOTIFICATION:

Customers of 1994 model year vehicles will be notified of the Special Policy by General Motors of Canada Limited. Customers of 1992-1993 vehicles were notified in March 1996. (See copies of owner letters included with this bulletin.)

CUSTOMER REIMBURSEMENT:

Customer claims for reimbursement on previously paid repairs to replace the cylinder head gasket that resulted in an engine coolant leak, were to have been submitted by March 1, 1997 for 1992 and 1993 vehicles. For 1994 vehicles, claims must be submitted by October 1, 1998. Repairs must have occurred within seven years of the date the vehicle was originally placed in service, or 160,000 km, whichever occurs first. Owners must submit original documentation which reasonably confirms the amount of unreimbursed repair expense(s), a description of the repair, date of the repair, and the person or entity performing the repair. Claims for. customer reimbursement of previously paid repairs are to be submitted as a Net Item Dollar Amount or a Warranty Claim.

If the work was done by someone other than a GM dealership the amount of reimbursement may be limited to the amount the repair would have cost GM to have it completed by a GM dealership. Dealers must receive the have it completed by a GM dealership. Deal original paid receipts or invoices verifying the repair, the amount charged, proof of payment, and the date of payment of those charges by October 1, 1998 for 1994 vehicles.

SERVICE PROCEDURE:

Install a new cylinder head gasket using the procedure outlined in Section 6A2 or the Engine Section in the Service Manual.

Some early 1994 model Chevrolet Cavalier models were assembled with engines that did not have a cooling system bleed valve on the cooling system water outlet adapter. If one of the above vehicles is being repaired, inspect the vehicle for a cooling system bleed valve on the water outlet adapter, if the vehicle has one, proceed with repairs. If there is a small pipe plug and no bleed valve, remove the plug and install a bleed valve, GM P/N 10070107 and proceed with repairs.

IMPORTANT:

Cylinder head flatness specification:

The cylinder head can be reused if the cylinder head warpage is less than 0.05 mm (0.002 in.) within any 152 mm (6.0 in.) area of the cylinder head sealing surface or 0.1 mm (0.004 in.) over the entire length of the cylinder head.

Resurface the cylinder head of warpage is over 0.05 mm (0.002 in.) within any 152 mm (6.0 in.) area, or more than 0.1 mm (0.004 in.) and less than 0.25 mm (0.010 in.) over the entire length of the cylinder head.

The cylinder head must be replaced if warpage is over 0.25 mm (0.010 in.).

NOTICE:

Never use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder bead and the block Abrasive pads will produce a fine grit that the oil filter will not be able to remove from the oil. THIS GRIT IS ABRASIVE AND HAS BEEN KNOWN TO CAUSE INTERNAL ENGINE DAMAGE. Also, abrasive pads may round the cylinder head edges or remove enough metal during cleaning to affect cylinder head flatness, both of which are known to affect the cylinder head gasket seal.

COOLANT FILL PROCEDURE (1994 Models Only)

1. Loosen the engine coolant air bleed screw located on the top side of the engine coolant outlet.

2. Add coolant to the radiator until all air is evacuated through the air bleed valve.

3. Tighten the air bleed valve screw.

4. Add two crushed cooling system sealing pellets GM P/N 3634621 to the radiator.

5. Fill the radiator until coolant begins to flow into the coolant recovery hose.

6. Install the pressure cap on the radiator.

7. Check the coolant level in the coolant recovery reservoir and fill to approximately 10mm (0.40in) above the "Full Hot" line.

8. Block the drive wheels and firmly apply the parking brake.

9. Shift automatic transaxle to "Park" and manual transaxle to "Neutral".

10. Run the engine at idle until the upper radiator hose is hot to the touch.

11. Allow the engine to cool and observe the coolant level in the coolant recovery reservoir, the coolant should be at a level between the "Full Cold" and "Full Hot" markings. If the coolant is below the "Full Cold" marking, add coolant to bring the level in the reservoir up to the "Full Cold" line.

CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

REPAIR PERFORMED PARTS LABOUR LABOUR ALLOW 0P HOURS

Cylinder Head Gasket - Replace * T8214 3.9

To clean parts on vehicles over **.2 48,000 km (30,000 miles)

Reimbursement T8215 ***.2 Administrative Labour Hours

* The "PARTS ALLOWANCE" should be the sum total of the current GMSPO dealer net price plus 30% for 1992 and 1993 models or 40% for 1994 models for all parts required for the repair.

** Add Times

*** 0.2 hour dealer administrative allowance which is entered as regular hours in the Warranty Claim Submission. The appropriate customer reimbursement is to be entered in the claim submission with the current order date and the current odometer reading and as a net dollar amount.

October 1997

Dear General Motors Customer:

As the owner of a 1994 Chevrolet Cavalier equipped with a 2.2L engine, your satisfaction with our product is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you should experience problems with your vehicle.

This letter is intended to make you aware that some 1994 Chevrolet Cavalier models with 2.2L engines may develop a failure of the cylinder head gasket that allows coolant to leak from the cylinder head gasket to engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odour of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

General Motors of Canada Limited is therefore taking the following action:

We are providing owners with special coverage. If the above mentioned condition occurs within seven (7) years of the date your vehicle was originally placed in service or 160,000 km, whichever occurs first, your vehicle will be repaired for you at no charge. This special policy applies only to repairs requiring cylinder head gasket replacement as a result of cylinder head gasket failure that results if an engine coolant leak. It does not cover engine damage from continuing to operate the engine in an overheated condition after loss of coolant.

This is not a recall campaign. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. Keep this letter with your other important glovebox literature for future reference.

If you have already paid for some or all of the cost to have the cylinder head gasket replaced and in-service time was less than seven (7) years and 160,000 km, you should contact your GM dealer. You may be eligible for partial or complete reimbursement of costs if genuine GM parts were used in the repair. If the work was done by someone other than a GM dealership the amount of reimbursement may be limited to the amount the repair would have cost GM to have it completed by a GM dealership. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, and the date of payment of those charges by October 1, 1998.

Repairs and adjustments qualifying under this Special Policy coverage must be performed by your GM Dealer.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

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

Customer Support Department General Motors of Canada Limited

97036

JL:il

March 1996

Dear General Motors Customer:

As the owner of a 1992 or 1993 Chevrolet Cavalier equipped with a 2.2L engine, your satisfaction with our product is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you should experience problems with your vehicle.

This letter is intended to make you aware that some 1992 and 1993 Chevrolet Cavalier models with 2.2L engines may develop a failure of the cylinder head gasket that allows coolant to leak from the cylinder head gasket to engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odour of coolant from the engine compartment, or a low coolant lamp. There may also be visible coolant deposits at the cylinder head to engine block joint.

General Motors of Canada Limited is therefore taking the following action:

We are providing owners with special coverage. If the above mentioned condition occurs within seven (7) years of the date your vehicle was originally placed in service or 160,000 km, whichever occurs first, your vehicle will be repaired for you at no charge. This special policy applies only to repairs requiring cylinder head gasket replacement as a result of cylinder head gasket failure that results in an engine coolant leak. It does not cover engine damage from continuing to operate the engine in an overheated condition after loss of coolant.

Repairs and adjustments qualifying under this Special Policy coverage must be performed by your GM Dealer.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

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

Customer Support Department General Motors of Canada Limited

6S01 LM:il

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.