Special Policy 00010-Coolant Loss,Leakage,Odor-Caused by Head Gasket Failure

Some customers of 1996 Chevrolet Cavalier, S10; Pontiac Sunfire; and GMC Sonoma model vehicles, equipped with 2.2L engine (RPO LN2-VIN Code 4) may experience 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 odor of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

This special policy covers the condition described above for a period of seven (7) years or 100,000 miles (160,000 km), whichever occurs 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 damage from continuing to operate the engine in an overheated condition after loss of coolant.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 23, 2000 are covered by this special policy and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to May 23, 2000 must be submitted to the Service Contract provider.

Involved are all 1996 Chevrolet Cavalier, S10; Pontiac Sunfire; and GMC Sonoma model vehicles equipped with 2.2L engine (RPO LN2-VIN Code 4) and built from Start of Production to End of Production, which begins and ends with the following VIN breakpoints:

Parts required to complete this Special Policy are to be obtained from General Motors Service Parts Operations (GMSPO).

Customers will be notified of the Special Policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin -- actual divisional letter may vary slightly).

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

Important: Cylinder head flatness specification:

Notice: Never use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head 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 Procure -- J-Car

1. Loosen the engine coolant air bleed screw located on the top side of the engine coolant outlet, under the preplenum duct.
2. Add coolant to the surge tank until all air is evacuated through the air bleed valve.
3. Tighten the air bleed valve screw.
4. Add five crushed cooling system sealing pellets, GM P/N 12378254 to the surge tank.
5. Fill the surge tank until the coolant is between the FULL COLD and FULL HOT markings.
6. Install the pressure cap on the surge tank.
7. Block the drive wheels and firmly apply the parking brake.
8. Shift and automatic transaxle to PARK and a manual transaxle to NEUTRAL.
9. Run the engine at idle until the upper radiator hose is hot to the touch.
10. ALLOW THE ENGINE TO COOL AND OBSERVE THE COOLANT LEVEL IN THE SURGE TANK. THE COOLANT SHOULD BE AT A LEVEL BETWEEN THE FULL COLD AND THE FULL HOT MARKINGS. IF THE COOLANT IS BELOW THE FULL COLD MARKING, ADD COOLANT TO BRING THE LEVEL IN THE SURGE TANK UP TO THE FULL COLD LINE.

Coolant Fill Procedure -- S-Truck

1. Ensure that the radiator drain cock is closed.

Notice: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze can freeze at -22°C (-8°F)

2. Pre-mix the coolant at a ratio of 50/50 with clean, drinkable water.
3. Place a large mouth funnel in the radiator fill opening.
4. Slowly add the coolant mixture.
5. Fill to 1/2 inch (1.25 cm) below the radiator fill opening.
6. Start the engine.
7. As the cooling system warms up and the thermostat opens, the coolant level will drop.
8. Add coolant until the level is up to the radiator fill opening.

•	Do not spill the coolant onto the exhaust system or other hot exhaust parts.

•	Under some conditions, coolant is combustible.

9. Replace the radiator filler cap.

For vehicles repaired under the terms of this Special Policy, submit a claim with the information indicated below:

Customer requests for reimbursement of previously paid repairs to replace the cylinder head gasket that resulted in an engine coolant leak, are to be submitted prior to or by May 31, 2002 (this time limitation may be longer depending upon the law in your state/province/country). Repairs must have occurred within the seven (7) years of the date the vehicle was originally placed in service, or 100,000 miles (160,000 km), whichever occurs first.

When a customer requests reimbursement, they must provide the following:

Customers from the States of California, Connecticut, Virginia, and Wisconsin must submit requests for reimbursement directly to <Divisions> per instructions in the owner letter.

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

As the owner of a 1996 Chevrolet Cavalier, S10, Pontiac Sunfire or GMC Sonoma equipped with a 2.2L engine, your satisfaction with our product is very important 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 1996 Chevrolet Cavalier, S10; Pontiac Sunfire and GMC Sonoma model vehicles; equipped with 2.2L engines, may develop a failure of the cylinder head gasket that allows coolant to leak from the cylinder head gasket to the engine block joint. Early evidence of this would 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 address the above mentioned condition, General Motors is providing owners with special warranty coverage. If this condition occurs on your 1996 Chevrolet Cavalier, S10; Pontiac Sunfire or GMC Sonoma model vehicle within seven (7) years of the date your vehicle was originally placed in service or 160,000 km (100,000 miles), whichever occurs first, the condition will be repaired for you at no charge.

This is not a recall campaign. Do not bring your vehicle to us as a result of this letter unless you believe that your vehicle has the condition as described above.

If you have already paid for some or all of the cost to have the cylinder head gasket replaced, you have not received reimbursement under a vehicle service contract, and the in-service time and mileage were less than seven (7) years and 160,000 km (100,000 miles), you should contact us to seek reimbursement. Please provide us with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documentation mentioned above, must be received by us by May 31, 2002.

Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer. You may want to call our service department to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will allow us to order parts if they are not already in stock. Keep this letter with your other important glovebox literature for future reference.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

GMODC

General Motors Corporation

Dear<<Division(s)>> Customer:

As the owner of a 1996 Chevrolet Cavalier, S10; Pontiac Sunfire or GMC Sonoma, equipped with a 2.2L engine, your satisfaction with our product is very important to us. Your vehicle was provided with a new 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 1996 Chevrolet Cavalier, S10; Pontiac Sunfire and GMC Sonoma model vehicles, equipped with 2.2L engines, may develop a failure of the cylinder head gasket that allows coolant to leak from the cylinder head gasket to the engine block joint. Early evidence of this would be a loss of coolant in the coolant reservoir and an odor of coolant from the engine compartment. There may also be visible coolant deposits at the cylinder head to engine block joint.

To address the above mentioned condition, General Motors is providing owners with special warranty coverage. If this condition occurs on your 1996 Chevrolet Cavalier, S10; Pontiac Sunfire or GMC Sonoma model vehicle within seven (7) years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, the condition will be repaired for you at no charge.

This is not a recall campaign. Do not take your vehicle to your <Division> dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

If you have already paid for some or all of the cost to have the cylinder head gasket replaced, and your in-service time and mileage was less than seven (7) years and 100,000 miles (160,000 km), you should contact your dealer to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. Your request for reimbursement, including the information and documents mentioned above, must be received by your dealer by May 31, 2002.

If you have already paid for some or all of the cost to have the cylinder head gasket replaced, and your in-service time and mileage was less than seven (7) years and 100,000 miles (160,000 km), you should write to (divisional specific address) to seek reimbursement. Please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of payment, the date of payment of those charges, and proof of ownership of the vehicle at the time of the repair. This information must be provided within two (2) years after the date on which you paid for the repair or by May 31, 2002, whichever is greater.

Repairs and adjustments qualifying under this special coverage must be performed by a <Division> dealer. You may want to call the service department at the dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glovebox literature for future reference.

Should your dealer be unable to schedule a service date within a reasonable amount of time, or you have any questions regarding this special policy, you should contact the appropriate Customer Assistance Center at the number listed below:

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

<<Division(s)>>

General Motors Corporation

Enclosure