CAMPAIGN: INTAKE MANIFOLD GASKET
Subject: Intake Manifold Gasket
Models: 1992-93 Chevrolet Cavalier, Corsica and Beretta, Oldsmobile Cutlass Ciera and Buick Century with 2.2L Engine (RPO LN2)
TO. ALL GENERAL MOTORS DEALERS:
General Motors of Canada Limited has determined that certain 1992-93 Chevrolet Cavalier, Corsica and Beretta, Oldsmobile Cutlass Ciera and Buick Century model vehicles equipped with 2.2L Engines (RPO LN2; VIN Code "4") may have been assembled with an intake manifold gasket that can move out of position due to engine thermo cycling. This may result in rough idling, a check engine light coming on, stalling and/or hesitation on acceleration.
To prevent this condition from occurring, dealers are to replace the intake manifold gasket on involved vehicles.
VEHICLES INVOLVED:
Involved are certain 1992-93 Chevrolet Cavalier, Corsica and Beretta, Oldsmobile Cutlass Ciera and Buick Century model vehicles equipped with 2.2L Engines (RPO LN2) and built within the following VIN breakpoints:
Year Model Plant Plant Code From Through
1992 Chev 'J' Lordstown "7" N7100001 N7325951 1993 Chev 'J' Lordstown "7" P7100001 P7338057 1992 Chev 'J' Ramos "S" NS800001 EOP 1993 Chev 'J' Ramos "S" PS800001 PS841644 1992 Chev 'L' Willmington "Y" NY100001 NY297283 1993 Chev 'L' Willmington "Y" PY100001 PY272840 1993 Olds 'A' Oklahoma City "6" P6334843 P6452251 1993 Buick 'A' Oklahoma City "6" P6400003 P6491481
NOTE: PLEASE CHECK DCS SCREEN 45 OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAID.
All effected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.
DEALER CAMPAIGN RESPONSIBILITY
All unsold new vehicles in dealer's possession and subject to this campaign must be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.
Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.
Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.
CAMPAIGN PROCEDURE
Refer to Section 4 of the Service Polices and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.
OWNER NOTIFICATION
All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.
PARTS INFORMATION
Parts required to complete this campaign should be ordered through regular channels, as follows:
Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 24574409 Intake Manifold Gasket 1
PARTS AND LABOUR CLAIM INFORMATION
Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:
Repair Code Description Time Allowance ----------- ----------- -------------- 1A Vehicle Previously Repaired with Correct Lower .3 Intake Manifold Gasket (Part #24574409) Only Requires Installation of Campaign Identification Label 2A 1992 Cavalier with A.T. 1.9 3A 1992 Cavalier with M.T. 1.8 4A 1992 Corsica/Beretta with A.T. 1.9 5A 1992 Corsica/Beretta with M.T. 1.8 9A 1993 Cavalier 1.9 AA 1993 Corsica/Beretta 1.9 BA 1993 Century/Ciera 1.4
Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.
SERVICE PROCEDURE:
1. Disconnect negative battery cable after noting radio settings.
2. Relieve fuel pressure according to Service Manual, Section 6E3-C2.
3. Remove air cleaner duct assembly and top half of the air cleaner.
4. Drain and recover coolant, refer to Section 6B of applicable Service Manual.
5. Remove torque strut from engine and rotate engine forward (Century and Ciera only).
6. Disconnect vacuum lines from the fuel pressure regulator, EGR, PCV and power brake booster.
7. For vehicles equipped with automatic transaxles, position transaxle fill tube and indicator assembly aside referring to appropriate Service Manual, Section 7A.
8. Remove throttle cable splash shield (Cavalier, Corsica and Beretta), throttle modulator cover (Century and Ciera), throttle cables and throttle cable bracket, refer to applicable Service Manual.
9. For 1993 models, disconnect secondary ignition wiring from the spark plugs and relocate ignition wiring harness.
10. Route power steering lines under the air inlet blower case.
11. Loosen the power steering pencil brace bolt at the power steering pump and remove the power steering pencil brace bolt at the intake manifold. Position brace aside (do not remove from vehicle).
12. For Beretta and Corsica models, position the main engine harness which runs along the front of dash towards the top of the front of dash. For Cavaliers, position the generator harness to the pulley side of the power steering pump.
13. Loosen the fuel line retainer under the intake manifold, refer to applicable Service Manual, Section 6C.
14. Remove the fuel feed hose retainer from the intake manifold, refer to applicable Service Manual, Section 6C.
15. Disconnect both fuel lines from the intake manifold, refer to applicable Service Manual, Section 6C.
16. Remove the lower intake manifold nuts.
17. Remove the four upper intake manifold studs from the cylinder head (Cavalier, Corsica and Beretta only).
18. Remove the intake manifold assembly (with plenum) from the cylinder head.
19. Clean and inspect the intake manifold and cylinder head mating surfaces.
Notice: Mating surfaces must be clean and free of any foreign material, grease or dirt.
Do not sand or rough up either of the mating surfaces prior to installation of the new gasket.
20. Install the new intake gasket and manifold assembly.
Notice: To prevent damage to gasket, install the Lower Intake Manifold Gasket against the cylinder head before installing the intake manifold.
Do not use any additional materials or sealants to improve the gasket sealing ability.
21. Install and tighten four upper intake manifold studs into the cylinder head (Cavalier, Corsica and Beretta only).
22. Tighten the intake manifold fasteners in sequence to the specification shown in applicable Service Manual, Section 6A2.
23. Connect both fuel lines to the intake manifold, refer to applicable Service Manual, Section 6C.
24. Install the fuel feed hose retainer to the intake manifold, refer to applicable Service Manual, Section 6C.
25. Route the fuel line under the fuel line retainer and tighten retainer, refer to applicable Service Manual, Section 6C.
26. Route the wiring harness to its original location, refer to Service Manual, Section 8A.
Reinstall power steering pump pencil brace as follows:
27. Return the power steering pump pencil brace.
- Install and tighten the power steering pump pencil brace to intake manifold bolt.
- Tighten the power steering pump pencil brace to pump bolt. Refer to appropriate Service Manual, Section 3B.
28. Route power steering lines to the correct position.
29. For 1993 models, route and reconnect secondary ignition wiring.
30. Reinstall throttle cable splash shield, throttle cables and throttle cable bracket (Cavalier, Corsica and Beretta), throttle modulator cover (Century and Ciera), refer to applicable Service Manual, Section 6C.
31. For vehicles equipped with automatic transaxles, reposition transaxle fill tube and indicator assembly, refer to applicable Service Manual, Section 7A.
32. Reconnect vacuum lines to the fuel pressure regulator, EGR, PCV and power brake booster.
33. Reinstall torque strut to engine (Century and Ciera only).
34. Refill engine coolant, refer to Section 6B of applicable Service Manual.
35. Reinstall air cleaner duct assembly and top half of the air cleaner.
36. Reconnect negative battery cable and reset radio settings and clock.
37. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks. If any leaks are detected repair as necessary.
38. Install Campaign Identification Label.
INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL
Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.
Dear General Motors Customer:
General Motors of Canada Limited has determined that certain 1992-93 Chevrolet Cavalier, Corsica and Beretta, Oldsmobile Cutlass Ciera and Buick Century model vehicles equipped with 2.2L Engines have been assembled with a lower intake manifold gasket that can move out of position due to engine thermo cycling. This may result in rough idling, a check engine light coming on, stalling and/or hesitation on acceleration.
To correct this condition, your dealer will replace the lower intake manifold gasket on your vehicle.
This service will be provided for you at no charge.
Please contact your GM dealer as soon as possible to arrange a service date.
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.
This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle 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.
Customer Support Department General Motors of Canada Limited
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.
