INFO. ON ENGINE EXCHANGE PROGRAM FOR 5.7L LS1 GEN III

SUBJECT: INFORMATION ON ENGINE EXCHANGE PROGRAM FOR 5.7L LS1 GEN III V8

MODELS: 1997 CHEVROLET CORVETTE WITH 5.7L V8 ENGINE (VIN G - RPO LS1)

THIS BULLETIN COVERS AN ENGINE EXCHANGE AND PART RESTRICTION PROGRAM FOR THE 1997 5.7L LS1, GEN III V8 ENGINE. THE ENGINE EXCHANGE AND PART RESTRICTION PROGRAM IS IN EFFECT UNTIL JUNE 30, 1997. ITS PURPOSE IS TO PROVIDE EARLY PRODUCT FEEDBACK AND INCREASE CUSTOMER SATISFACTION.

ALL REQUIREMENTS REGARDING SERVICEABILITY AND NON-SERVICEABLE ITEMS, WARRANTY CLAIMS, PROCESSING PROCEDURES AND SHIPPING INSTRUCTIONS ARE EXPLAINED IN THIS BULLETIN. YOUR COOPERATION IN FOLLOWING THESE PROCEDURES WILL GREATLY IMPROVE THE EFFECTIVENESS OF THIS PROGRAM.

NEW FEATURES OF THE 5.7L LS1 GEN III V-8:

COMPOSITE INTAKE MANIFOLD DUAL WALL EXHAUST MANIFOLDS EQUALLY SPACED INTAKE AND EXHAUST PORTS 1.70:1 RATIO ROLLER ROCKERS COVERED VALLEY EXTENDED SUMP STRUCTURED OIL PAN GEROTOR OIL PUMP ELECTRONIC THROTTLE CONTROL (ETC) SIX BOLT MAIN CAPS COIL NEAR PLUG IGNITION (INSTALLED ON ROCKER COVERS) DEEP SKIRT ALUMINUM BLOCK DISTRIBUTORLESS IGNITION SYSTEM (CAM AND CRANK SENSOR) 24X RELUCTOR RING KNOCK SENSORS MOUNTED IN ENGINE VALLEY ALL METRIC FASTENERS IF ANY INTERNAL COMPONENTS REQUIRE REPLACEMENT, OR THERE ARE ANY MAJOR ENGINE LEAKS (OIL OR COOLANT), THE ENGINE MUST BE EXCHANGED.

ENGINE COMPONENTS WHICH MAY BE SERVICED (WITHOUT EXCHANGE): SEE * FOR RESTRICTED PARTS.

ACCESSORY DRIVE BELT, TENSIONER, AND PULLEYS CRANK SENSOR SPARK PLUGS WATER PUMP SPARK PLUG WIRES GENERATOR COILS A/C COMPRESSOR STARTER P/S PUMP AND PULLEYS FUEL INJECTORS INTAKE MANIFOLD O2 SENSORS KNOCK SENSORS PCM* CAM SENSOR THROTTLE BODY* THERMOSTAT TAC MODULE* ROCKER COVERS ACCELERATOR PEDAL MODULE* MAP SENSOR

* IMPORTANT: THESE COMPONENTS ARE UNDER A PARTS RESTRICTION. THESE PARTS ARE NEW FOR 1997 AND A PART RESTRICTION PROGRAM WAS SET UP TO GAIN ENGINEERING FEEDBACK. FOR SERVICE PROCEDURES OF THESE COMPONENTS CONTACT THE CORVETTE LAUNCH CENTER (1-800-498-5148). CANADIAN DEALERS SHOULD CONTACT TAC AT 1-800-263-7740.

PROCEDURES FOR THESE SERVICE OPERATIONS ARE IN THE 1997 CORVETTE SERVICE MANUAL. UPON COMPLETION OF YOUR DIAGNOSIS, ALL PARTS MUST BE REINSTALLED.

COMPLETE ENGINES MUST BE RETURNED

ENGINE EXCHANGE PROCEDURE:

ONCE THE ABOVE PRELIMINARY DIAGNOSIS IS MADE AND AN EXCHANGE IS DEEMED NECESSARY, CONTACT THE CORVETTE LAUNCH CENTER (1-800-498-5148). CANADIAN DEALERS SHOULD CONTACT TAC AT 1-800-263-7740.

THE CENTER WILL ARRANGE WITH THE ENGINE PLANT TO DIRECTLY SHIP A REPLACEMENT ENGINE WITHIN TWO WORKING DAYS. A TAN CASE NUMBER WILL BE PROVIDED FOR EACH ENGINE EXCHANGE. THIS NUMBER MUST BE RECORDED ON THE IDENTIFICATION CARD SUPPLIED WITH THE REPLACEMENT ENGINE AND MUST BE AFFIXED TO THE REPLACED ENGINE BEING RETURNED. THE IDENTIFICATION CARD MUST BE FILLED OUT COMPLETELY. TO AVOID A CHARGE BACK, THE EXCHANGED UNIT MUST BE SHIPPED WITHIN 48 HOURS IN THE ORIGINAL SHIPPING CONTAINER. FAILURE TO RETURN THE UNIT WILL RESULT IN THE DEALERSHIP BEING BILLED THE FULL VALUE OF THE EXCHANGED UNIT.

ALL PROCEDURAL STEPS MUST BE FOLLOWED TO ENSURE THE DEALERSHIP IS NOT BILLED IN ERROR.

THE REMOVED UNIT MUST BE RETURNED COMPLETELY AS REMOVED FROM THE VEHICLE IN THE CONTAINER PROVIDED, WITHOUT EXAMINATION OF THE UNIT OTHER THAN AS DESCRIBED IN THE PARAGRAPH ENTITLED "ENGINE COMPONENTS WHICH MAY BE SERVICED (WITHOUT EXCHANGE)". ALL INCIDENTAL ITEMS ON THE REMOVED UNIT MUST REMAIN THE SAME AS THE REPLACEMENT ENGINE SHIPPED (I.E., IGNITION SYSTEM, 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.

THE EXCHANGE UNIT WILL BE SHIPPED WITH A QUANTITY OF OIL; CHECK OIL LEVEL BEFORE STARTING ENGINE.

INCLUDED WITH THE EXCHANGE UNIT WILL BE A RETURN SHIPPING LABEL (FREIGHT COLLECT AT DESTINATION) AND A PARTIALLY COMPLETED BILL OF LADING.

PREPARATION FOR SHIPPING:

ENGINE MUST BE RETURNED EMPTY OF FLUIDS. DRAIN OIL PAN AND CYLINDER BLOCK. IF A LEAK IS THE CAUSE FOR THE EXCHANGE, COPY THE ATTACHED ENGINE ART WHICH PERTAINS TO THE AREA OF THE LEAK, IDENTIFY THE AREA ON THE PHOTO COPY AND RETURN IT WITH THE ENGINE. (SEE FIGURES 1-6)

REMOVE THE ENGINE ASSEMBLY AS OUTLINED IN THE 1997 SERVICE MANUAL. REMOVE ANY PLASTIC SHIPPING PLUGS AND COVERS FROM THE EXCHANGE UNIT AND INSTALL THEM ON THE REMOVED UNIT.

WRITE THE TAN REFERENCE NUMBER ON THE REPAIR ORDER FORM.

PLACE THE REMOVED UNIT INTO THE ORIGINAL SHIPPING CONTAINER. INCLUDE A COPY OF THE REPAIR ORDER AND THE COMPLETED IDENTIFICATION CARD IN AN ENVELOPE AND ATTACH TO REPLACED ENGINE.

SHIPPING INSTRUCTIONS:

REMOVE THE ORIGINAL SHIPPING TAG AND ATTACHED THE RETURN SHIPPING TAG TO THE CONTAINER.

THE BILL OF LADING PROVIDED WITH THE EXCHANGE IS THE ONLY DOCUMENT REQUIRED TO RETURN SHIP THE REMOVED ENGINE.

IMPORTANT: THE CARRIER, WHOSE NAME AND PHONE NUMBER ARE INDICATED ON THE BILL OF LADING, SHOULD BE USED FOR THE RETURN ENGINE SHIPMENT. GROUND FREIGHT ONLY.

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 COPIES TO THE CARRIER. YOUR COPY OF THE BILL OF LADING, SIGNED BY THE CARRIER, IS YOUR PROOF OF RETURNING THE ENGINE.

THE REMOVED ENGINE IS TO BE SHIPPED BY TRUCK FREIGHT COLLECT TO:

GM POWERTRAIN DIVISION ROMULUS ENGINE OPERATIONS 36880 ECORSE RD ROMULUS, MI 48174-0910

TO ASSURE THE EFFECTIVENESS OF THE PROGRAM, THE REMOVED UNIT SHOULD BE RETURNED IMMEDIATELY. FAILURE TO RETURN THE REMOVED UNIT WILL RESULT IN THE DEALERSHIP BEING BILLED THE NET COST FOR THE UNIT FURNISHED, PLUS AN ADMINISTRATION CHARGE.

WARRANTY INFORMATION:

OPERATION DESCRIPTION OPERATION NUMBER

REPLACE ENGINE ASSEMBLY J1880

THE FOLLOWING INFORMATION SHOULD BE USED FOR CLAIM SUBMISSION:

LABOR OPERATION LABOR OTHER* PART** NUMBER DESCRIPTION HOURS HOURS ALLOWANCE -------------------------------------------------------------------- J1880 REPLACE ENGINE ASSEMBLY 8.8 0.2 $760.80 MANUAL APPLICATION $682.00 AUTOMATIC APPLICATION

* ADMINISTRATIVE ALLOWANCE ** THE AMOUNT IDENTIFIED IN THE "PART ALLOWANCE" COLUMN ABOVE REPRESENTS 40% OF THE PRELIMINARY GMSPO DEALER PRICE AND THE RETURN CREDIT (CORE ALLOWANCE). THIS AMOUNT IS TO BE PLACED IN THE "NET AMOUNT" COLUMN OF THE CLAIM.

IMPORTANT: APPLICABLE MISCELLANEOUS ITEMS, SUCH AS ENGINE OIL AND ENGINE COOLANT, SHOULD BE ADDED TO THE PART ALLOWANCE AMOUNT AND INCLUDED IN THE NET AMOUNT (DMN) COLUMN OF THE WARRANTY CLAIM.

**INSERT FIGURES** TPOLS101 TPOLS102 TPOLS103 TPOLS104 TPOLS105 TPOLS106

FIGURES: 6 ATTACHMENTS: 0

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.

COPYRIGHT 1996. GENERAL MOTORS CORPORATION. ALL RIGHTS RESERVED.