ENGINE EXCHANGE PROGRAM 6.5 TURBO DIESEL-SERVICE INFO

Subject: ENGINE EXCHANGE PROGRAM - 1992 6.5L TURBO DIESEL (L65-VIN CODE F)

Model and Year: 1992 C/K TRUCKS WITH 6.5L TURBO DIESEL ENGINE -----------------------------------------------------------------------------

TO GAIN NEEDED PRODUCT FEEDBACK ON THE NEW VERSION OF THE 6.5L TURBO DIESEL ENGINE (L65 VIN CODE F), AN EXCHANGE PROGRAM IS NOW IN EFFECT AND WILL CONTINUE FOR THE 1992 MODEL YEAR.

The exchange program will be administered by the Chevrolet Technical Assistance Network (TAN).

This information should be filed in the "Special Exchange Policy Procedures" manual previously provided.

If your dealership receives a customer concern on this engine, follow the procedure below.

A. DIAGNOSIS --------- If any internal engine components require replacement, the engine must be exchanged. Only the valve rocker covers and oil pan may be removed to determine whether the engine must be replaced. Generally, any external components (e.g., water pump, fuel nozzle, etc.) may be serviced without requesting engine exchange. If a replacement engine is needed, any of the above mentioned parts that were removed must be reinstalled (i.e., complete engines are required for exchange).

B. EXCHANGE PROCEDURE ------------------ Once the above diagnosis is made and an exchange engine is deemed necessary, call the Chevrolet Technical Assistance Network - Miscellaneous Group at 1-800-227-3175.

- TAN will require the VIN and engine serial number along with a description of your diagnosis.

- TAN will arrange to ship a replacement engine within 48 hours and provide you with a TAN reference number.

- The replacement engine will be complete except for accessories (i.e., starter, generator, fuel system, etc.).

- The replacement engine will be shipped with minimum oil quantity; add oil per specifications.

- The replacement engine will also include an envelope with the following:

- Return shipping label - Identification card - Bill of Lading

C. PREPARATION FOR SHIPPING ------------------------ The removed engine must be returned in the container provided, without examination other than as described in section A above. Engine dress must remain the same as the replacement engine (i.e., manifolds, throttle body, etc.). Dealerships returning units even partially disassembled will be judged as violating this procedure and as such will be subject to being billed for all materials furnished.

Visually check all fluid levels to assure they are within the normal operating range. If not, drain and measure the oil and coolant from the concerned unit. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG.

Remove the engine assembly as outlined in the 1992 Service Manuals.

Remove all plastic shipping plugs and, covers from the replacement engine and install them on the removed engine.

If the removed engine leaks, mark leak area on engine.

- Write the TAN reference number on the repair order and on the identification card provided.

- Fully complete the identification card.

- Place a copy of the repair order and the completed identification card in the original envelope and attach it to removed engine.

- Place the removed engine into the original shipping container.

D. SHIPPING INSTRUCTIONS --------------------- - Place the return shipping label provided over the original container shipping label.

- The Bill of Lading provided is the only document required to return ship the removed engine.

NOTE: The same carrier, whose name is indicated on the Bill of Lading, should be used for the return shipment.

- All required data on the Bill of Lading will be complete, except for the date and carrier signature. After the Bill of Lading has been dated and signed by the carrier, retain the last copy with your repair order and provide the other two copies to the carrier. Your copy of the Bill of Lading, signed by the carrier, is your proof of the engine return.

The removed engine is to be shipped by Truck Freight Collect to:

GM Powertrain Moraine Engine Plant 4100 Springbord Pike Dayton, Ohio 45439

ATTN: 6.5L (L65) Engine Exchange Program Quality Assurance Department

To increase the effectiveness of the program, the removed unit should be returned immediately after removal. Failure to return the removed unit, within 10 days, will result in the dealership being billed $4,900.00 for the unit furnished, plus an administration charge.

E. WARRANTY CLAIMS PROCESSING PROCEDURE ------------------------------------ Upon completion of the repair, submit a warranty claim as follows:

Labor Operation **Part Labor *Other Number Description Allowance Hours Hours --------- ----------- --------- ----- ------

Tl795 Replace Engine Assembly $435.00 5.2 .2

Add Time:

With Air Conditioning .2 With Cruise Control .1 With Engine Block Heater .1 With Automatic Transmission .8 With Strut Rods (K Truck only) .2

* Administration Allowance

** The amount identified in the "Part Allowance" column above represents 30% of dealer net price of the difference between the current GMSPO Dealer Net Price less the engine return credit (Core Allowance) for parts furnished. This is to be placed in the Net Amount column of the claim.

NOTE: Applicable miscellaneous items, such as engine oil and engine coolant, should be added to the above Part Allowance amount and included in the Net Amount (DMN) column of the claim.

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF THE REMOVED ENGINE WILL INCREASE PROGRAM EFFECTIVENESS. IF YOU HAVE ANY QUESTIONS CONCERNING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT THE CHEVROLET TECHNICAL ASSISTANCE NETWORK (MISCELLANEOUS GROUP).

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.