SPECIAL POLICY ADJUSTMENT PISTON PLATING WEAR
Subject: SPECIAL POLICY ADJUSTMENT PISTON PLATING WEAR
Model and Year: 1990 CHEVROLET LUMINA COUPE, SEDAN AND APV WITH 3.1 L ENGINE
To: All Chevrolet Dealers:
General Motors has determined that some 1990 Chevrolet Lumina Coupe, Sedan and APV model vehicles equipped with 3.1L engines may develop a condition of premature wear of the pistons due to low adhesion of the tin plating. Evidence of this condition would be a cold engine knocking noise at low ambient temperatures. This condition will not lead to engine failure and is typically limited to cylinders #2, #4, and #6.
VEHICLES INVOLVED:
Involved are some 1990 Chevrolet Lumina Coupe, Sedan and APV model vehicles equipped with 3.1 L engines and built within the following VIN breakpoints:
PLANT YR MODEL PLANT CODE FROM THROUGH -- ----- ----- ----- ---- ------- 1990 W-Car Oshawa #1 "9" L9100103 L9317955 1990 W-Car Oshawa #2 "1" L1100001 L1400248 1990 U-Van Tarrytown "T" LT100081 LT179091
SPECIAL POLICY ADJUSTMENT:
This special policy covers the condition described above on vehicles in specific cold climate states for a period of six years or 72,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. If piston replacement is required due to this condition, an engine replacement will be made at no charge to the owner rather than replacement of individual pistons. This Special Policy Adjustment applies ONLY to repairs required as a RESULT of the described condition; it does not cover other conditions which may necessitate a partial engine replacement.
This "Special Policy Adjustment Bulletin" should be filed in your "Special Policy Adjustment Bulletins" binder furnished to dealers by General Motors.
REIMBURSEMENT
Customer claims for reimbursement (including $100 deductible as stated in the warranty coverage) on previously paid repairs to replace pistons (or partial engine) as a result of premature piston wear due to low adhesion of tin plating, are to be submitted by August 31, 1994 (this time limitation may be longer depending upon the law in some states). Repairs must have occurred within 6 years of the date the vehicle was originally placed in service, or 72,000 miles, whichever occurs first.
Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity who performed the repair. Claims for customer reimbursement on previously paid repairs are to be submitted according to the Warranty Claim Information instructions. Use the "Owner Reimbursement" labor operation, and list all owner expenses concerning previous repairs in the net items column of the warranty claim.
OWNER NOTIFICATION:
Owners in specific cold climate states (see below) will be notified of this Special Policy by Chevrolet (see copy of owner letter included with this bulletin).
STATES INVOLVED IN OWNER NOTIFICATION:
Alaska (AK) Nebraska (NE) Colorado (CO) New Hampshire (NH) Connecticut (CT) New Jersey (NJ) Delaware (DE) New York (NY) Dist. of Columbia (DC) North Dakota (ND) Idaho (ID) Ohio (OH) Illinois (IL) Pennsylvania (PA) Indiana (IN) Rhode Island (RI) Iowa (IA) South Dakota (SD) Massachusetts (MA) Utah (UT) Maine (ME) Vermont (VT) Maryland (MD) Virginia (VA) Michigan (MI) West Virginia (WV) Minnesota (MN) Wisconsin (WI) Montana (MT) Wyoming (WY)
PARTS INFORMATION:
Parts are to be obtained from General Motors Service Parts Operations (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a "C.I.O." order with no special instruction code, but on an advise code (2).
PARTS FOR LUMINA COUPES AND SEDANS BUILT PRIOR TO VIN L9124965 OR VIN L1114223 ----------------------------------------------------------------------------- QUANTITY/ PART NO. DESCRIPTION VEHICLE -------- ----------- --------- 10089656 Partial Engine 1 12337894 Oil Filter Adapter Gasket 1 10094825 Seal Exhaust Manifold Pipe 1 12511885 Gasket Kit 1 (Gaskets For: Intake Manifold, Exhaust Manifold And Intake Plenum) 10189276 Front Cover Gasket 1 10151654 Oil Pan Gasket 1 10243247 Crankshaft Front Oil Seal 1 1052753 Engine Coolant (Bulk) 6.3 Qts. 25010908 Oil Filter (PF51) 1 12345612 Engine Oil, 5W-30 4.5 Qts. 3634621 Engine Coolant System Sealer 2 Pellets (Package Of 6 Pellets)
PARTS FOR LUMINA COUPES AND SEDANS BUILT AFTER VIN L9124965 OR VIN L1114223
QUANTITY/ PART NO. DESCRIPTION VEHICLE -------- ----------- --------- 12513153 Goodwrench Engine 1 10182374 Water Pump Gasket 1 12337894 Oil Filter Adapter Gasket 1 10104430 Plenum Gasket Kit 1 14100625 Exhaust Manifold Gasket 1 (Left Hand) 10078991 Exhaust Manifold Gasket 1 (Right Hand) 10094825 Exhaust Manifold Pipe Seal 1 1052753 Engine Coolant (Bulk) 6.3 Qts. 25010908 Oil Filter (PF51) 1 12345612 Engine Oil, 5W-30 4.5 Qts. 3634621 Engine Coolant System Sealer 2 Pellets (Package Of 6 Pellets)
PARTS FOR ALL LUMINA APV's -------------------------- QUANTITY/ PART NO. DESCRIPTION VEHICLE -------- ----------- --------- 12513152 Goodwrench Engine 1 12520756 Intake Manifold Gasket Kit 1 14092220 Throttle Body Gasket 1 1977935 Distributor 0-Ring 1 10182374 Water Pump Gasket 1 12337894 Oil Filter Adapter Gasket 1 10094825 Exhaust Manifold Pipe Seal 1 1052753 Engine Coolant (Bulk) 6.7 Qts. 12345612 Engine Oil, 5W-30 4.5 Qts. 25010908 Oil Filter (PF51) 1 3634621 Engine Coolant System Sealer 2 Pellets (Package Of 6 Pellets)
SERVICE PROCEDURE PARTIAL ENGINE PROCEDURE FOR LUMINA COUPES AND SEDANS BUILT PRIOR TO VIN L9124965 OR VIN L1114223
1. Disconnect battery cables. Be certain to note all radio and clock settings, etc. prior to disconnecting.
2. Remove hood assembly.
3. Remove air cleaner and duct assembly.
4. Drain engine coolant.
5. Disconnect upper and lower radiator hoses, heater hoses and remove coolant recovery tank.
6. Disconnect throttle valve cable at transmission (accessible from engine compartment).
7. Remove exhaust crossover pipe.
8. Remove ECM cover.
9. Remove serpentine belt.
10. Disconnect both upper engine mounts and rotate engine forward. See service manual section 6A.
11. Remove manifold absolute pressure (MAP) sensor and bracket.
12. Remove alternator assembly.
13. Remove throttle control cable and shield at throttle body.
14. Remove brake vacuum pipe at intake plenum and booster.
15. Remove throttle control cable at plenum bracket.
16. Remove power steering pump from engine and securely position at side. Do not disconnect power steering hoses from pump.
17. Remove wiring harness tie straps and disconnect upper wiring harness connectors.
18. Disconnect fuel lines at rail and bracket.
19. Disconnect upper electrical grounds at transaxle.
20. Disconnect vacuum modulator line at transaxle (accessible from engine compartment).
21. Disconnect oxygen sensor electrical connector.
22. Rotate engine back into normal position.
23. Raise vehicle.
24. Drain engine oil.
25. Remove oil filter.
26. Remove right-hand engine splash shield.
27. Disconnect front exhaust pipe from manifold.
28. Disconnect electrical connections at compressor, ignition module and speed sensor.
29. Remove A/C compressor pencil brace.
30. Remove flywheel cover.
31. Remove starter.
32. Disconnect lower ground strap at transaxle.
33. Remove torque convertor bolts.
34. Remove A/C compressor mounting bolts securely reposition compressor. Do not disconnect high or low A/C lines.
35. Remove transaxle support bracket bolts at transaxle.
36. Remove front engine mount nuts at frame.
37. Remove both lower bell housing bolts.
38. Lower vehicle.
39. Install engine lifting device.
40. Remove remaining bell housing bolts.
41. Install transaxle support.
42. Remove engine.
43. Remove flywheel.
44. Mount removed engine assembly on engine stand and remove lifting device.
45. Remove alternator mounting bracket and pencil brace.
46. Remove intake plenum with throttle body attached.
47. Remove ignition module assembly with spark plug wires attached.
48. Remove throttle body heater pipe.
49. Remove both rocker arm covers.
50. Remove heater hose pipe at intake manifold and cylinder head.
51. Remove intake manifold and gaskets.
52. Remove engine torque strut bracket.
53. Remove both exhaust manifolds and gaskets.
54. Remove cylinder heads. Refer to service manual for details of removal procedure (section 6A5).
55. Remove upper engine wiring harness.
56. Remove serpentine belt tensioner.
57. Remove crankshaft balancer mounting bolt and crankshaft balancer using tool J 24420-B.
58. Remove front engine mount bracket.
59. Remove oil pan.
60. Remove oil pump and oil pump driveshaft.
61. Remove timing chain cover.
62. Remove timing chain and sprockets. Refer to service manual for details of removal procedure (section 6A5).
63. Remove valve lifters and camshaft. Refer to service manual for details of camshaft removal procedure (section 6A5).
64. Remove electronic spark control (ESC) knock and crank sensor.
65. Remove oil filter adaptor.
66. Grind valves to recondition. Refer to service manual for details of inspection and measuring procedure (section 6A5).
67. Remove transaxle support bracket.
68. Remove engine oil level indicator (dipstick) and indicator tube. Caution should be taken in removing indicator tube. If the tube breaks during removal, a new tube must be obtained through GMSPO.
69. Remove old engine from stand.
70. Mount new partial engine on stand.
71. Install engine oil indicator tube and engine oil level indicator to new engine.
72. Install transaxle support bracket.
73. Install ESC knock sensor. Tighten sensor to 19 Nm 14 lb. ft.).
Notice: Be certain threads are clean.
74. Install crankshaft sensor. Refer to service manual for inspection and installation procedure (section 6E3-C4).
75. Install oil filter adaptor, including oil pressure sensor and new adaptor gasket. Tighten connector through adaptor to 39 Nm (29 lb. ft.).
76. Install camshaft and lifters. Refer to service manual for installation procedure (section 6A5).
77. Install oil pump drive shaft extension assembly.
Tighten bolt to 34 Nm (25 lb. ft.).
78. Install timing chain and sprockets. Refer to service manual for installation procedure (section 6A5).
79. Install timing chain damper. Tighten bolt to 21 Nm (15 lb. ft.).
80. Install timing chain cover, new gasket and new crankshaft front oil seal. Refer to service manual for cleaning and installation procedure (section 6A5).
81. Install oil pump and shaft. Tighten bolt to 41 Nm (30 lb. ft.).
82. Install oil pan and new oil pan gasket. Refer to service manual for cleaning and installation procedure (section 6A5).
83. Install front engine mount bracket. Tighten bolts to 85 Nm (63 lb. ft.).
84. Install crankshaft balancer. Refer to service manual for details of installation procedure (section 6A5).
85. Install serpentine belt tensioner. Tighten bolts to 54 Nm (40 lb. ft.).
86. Install upper engine wiring harness.
87. Install cylinder heads and new head gaskets. Refer to service manual for cleaning and installation procedure (section 6A5).
88. Install exhaust manifolds and new gaskets. Refer to service manual for details of cleaning and installation procedure (section 6A5).
89. Install engine torque strut bracket.
90. Install intake manifold and new gasket. Refer to service manual for cleaning and installation procedure (section 6A5).
91. Connect heater hose pipe at intake manifold and cylinder head.
92. Install both rocker arm covers and new gaskets. Refer to service manual for details of installation procedure (section 6A5).
93. Install throttle body heater pipe.
94. Install ignition module assembly with spark plug wires attached. Tighten bolts to 25 Nm (19 lb. ft.)
95. Install intake plenum with throttle body attached and new plenum gaskets. Connect coolant and vacuum hoses. Refer to service manual for cleaning and installation procedure.
96. Install alternator mounting bracket.
97. Install engine lifting devise and remove engine assembly from stand.
98. Install flywheel. Apply GM Thread Lock to all flywheel bolts and tighten bolts to 70 Nm (52 lb. ft.)
99. Install engine assembly in vehicle.
100. Install upper engine/transaxle bolts. Tighten bolts to 75 Nm (55 lb. ft.).
101. Remove support at transaxle.
102. Remove engine lifting device.
103. Raise Vehicle.
104. Install lower engine/transaxle bolts. Tighten bolts to 75 Nm (55 lb. ft.).
105. Install front engine mount nuts at frame. Tighten nuts to 45 Nm (34 lb. ft.).
106. Install transaxle support bracket bolts at transaxle. Tighten rear bolts to 83 Nm (61 lb. ft.) and front bolts to 43 Nm (35 lb. ft.).
107. Install A/C compressor and mounting bolts. Refer to service manual details of installation procedure (section 1 B).
108. Install torque convertor bolts. Tighten bolts to 60 Nm (44 lb. ft.).
109. Connect lower ground strap at transaxle.
110. Install starter.
111. Install flywheel cover. Tighten bolts to 10 Nm (89 lb. in.).
112. Install rear A/C compressor to starter pencil brace.
Refer to service manual for details on installation procedure (section 1 B).
113. Connect front exhaust pipe at manifold with new seal. Tighten bolts to 47 Nm (35 lb. ft.).
114. Install right-hand engine splash shield.
115. Install new oil filter.
116. Lower vehicle.
117. Rotate engine to forward position (see step 10).
118. Connect oxygen sensor electrical connector.
119. Connect vacuum modulator line at transaxle.
120. Connect upper electrical grounds at transaxle.
121. Connect fuel lines at rail and bracket.
122. Connect upper engine wiring harness connectors and install wiring harness tie straps.
123. Install power steering pump. Tighten bolts to 27.5 Nm (20.5 lb. ft.).
124. Install throttle control cable bracket at plenum.
125. Install brake vacuum pipe at plenum and booster.
126. Install throttle control cables at throttle body.
127. Install alternator assembly.
128. Install MAP sensor and bracket.
129. Rotate engine to normal position and connect both engine mounts.
130. Install serpentine belt.
131. Install ECM cover.
132. Install exhaust crossover pipe. Tighten bolts to 25 Nm (18 lb. ft.).
133. Connect throttle valve cable to transmission.
134. Connect upper and lower radiator hoses and heater hoses.
135. Install coolant recovery tank.
136. Install air cleaner and duct assembly.
137. Install hood.
138. Fill engine to appropriate level with new engine oil (approx. 4.5 qts.).
139. Reconnect battery cables.
140. Refill coolant system with new coolant. Add two (2) engine cooling system sealer pellets to radiator. Coolant must be mixed with an equal amount of water and coolant (50/50) to provide proper protection.
141. Start engine and verify no fluid leaks.
142. Reset radio, clock, etc.
GOODWRENCH ENGINE ASSEMBLY PROCEDURE FOR LUMINA COUPES AND SEDANS BUILT AFTER VIN L9124965 OR VIN L1114223
1. Disconnect battery cables. Be certain to note all radio settings, etc. prior to disconnecting.
2. Remove hood assembly.
3. Remove air cleaner and duct assembly.
4. Drain engine coolant.
5. Disconnect upper and lower radiator hoses, heater hoses and remove coolant recovery tank.
6. Disconnect throttle valve cable at transaxle (accessible from engine compartment).
7. Remove exhaust crossover pipe.
8. Remove ECM cover.
9. Remove serpentine belt.
10. Disconnect both upper engine mounts and rotate engine forward. Refer to service manual for rotating and locking engine into position (Figure 5 in section 6A5).
11. Remove manifold absolute pressure (MAP) sensor and bracket.
12. Remove alternator assembly.
13. Remove throttle control cable and shield at throttle body.
14. Remove brake vacuum pipe at plenum and booster.
15. Remove throttle control cable at plenum bracket.
16. Remove power steering pump from engine and securely reposition at side. Do not disconnect power steering hoses from pump.
17. Remove wiring harness tie straps and disconnect upper wiring harness connectors.
18. Disconnect fuel lines at rail and bracket.
19. Disconnect upper electrical grounds at transaxle.
20. Disconnect vacuum modulator line at transaxle (accessible from engine compartment).
21. Disconnect oxygen sensor electrical connector.
22. Rotate engine back into normal position.
23. Raise vehicle.
24. Drain engine oil.
25. Remove oil filter.
26. Remove right-hand engine splash shield.
27. Disconnect front exhaust pipe from exhaust manifold.
28. Disconnect electrical connections at compressor, distributor module and speed sensor.
29. Remove A/C compressor pencil brace.
30. Remove flywheel cover.
31. Remove starter.
32. Disconnect lower ground strap at transaxle.
33. Remove torque convertor bolts.
34. Remove A/C compressor mounting bolts and securely reposition compressor.
Notice: Do not disconnect either pressure line from compressor.
35. Remove transaxle support bracket bolts at transaxle.
36. Remove front engine mount nuts at frame.
37. Remove both lower bell housing bolts.
38. Lower vehicle.
39. Install engine lifting device.
40. Remove remaining bell housing bolts.
41. Install transaxle support.
42. Remove engine.
43. Remove flywheel.
44. Mount removed engine assembly on engine stand and remove lifting device.
45. Remove alternator mounting bracket and pencil brace.
46. Remove intake plenum with throttle body attached.
47. Remove ignition module assembly with spark plug wires attached.
48. Remove throttle body heater pipe.
49. Remove both rocker arm covers.
50. Remove heater hose pipe at intake manifold and cylinder head.
51. Remove intake manifold.
52. Remove engine torque strut bracket.
53. Remove both exhaust manifolds.
54. Remove upper engine wiring harness.
55. Remove serpentine belt tensioner.
56. Remove crankshaft balancer mounting bolt and crankshaft balancer using tool J 24420-B..
57. Remove front engine mount bracket.
58. Remove electronic spark control (ESC) knock sensor and crankshaft sensor.
59. Remove engine block heater, if equipped.
60. Remove oil filter adaptor.
61. Remove fuel line bracket.
62. Remove coolant temperature sensor.
63. Remove transaxle support bracket.
64. Remove water pump pulley.
65. Remove water pump.
66. Remove old engine from stand.
67. Mount new engine on stand.
68. Install new engine oil level indicator (dipstick) tube on new engine (tube packaged loose with Goodwrench engine).
69. Install new engine oil level indicator (dipstick) into indicator tube (indicator packaged loose with Goodwrench engine).
70. Install water pump and new gasket. Tighten bolts to 10 Nm (89 lb. in.)
71. Install water pump pulley.
72. Install transaxle support bracket.
73. Install coolant temperature sensor.
74. Install fuel line bracket.
75. Install oil filter adaptor, including oil pressure sensor, and new adaptor gasket. Tighten connector through adaptor to 39 Nm (29 lb. ft.).
76. Install engine block heater, if equipped.
77. Install ESC knock sensor. Tighten sensor to 19 Nm (14 lb. ft.).
Notice: Be sure threads are clean.
78. Install crankshaft sensor. Refer to service manual for inspection and installation procedure (section 6E3-C4).
79. Install front engine mount bracket. Tighten bolts to 85 Nm (63 lb. ft.).
80. Install crankshaft balancer. Refer to service manual for details of installation procedure (section 6A5).
81. Install serpentine belt tensioner. Tighten bolts to 54 Nm (40 lb. ft.).
82. Install upper engine wiring harness.
83. Install exhaust manifolds and new gaskets. Refer to service manual for details of cleaning and installation procedure (section 6A5).
84. Install engine torque strut bracket.
85. Install intake manifold. Refer to service manual for cleaning and installation procedure (section 6A5).
86. Connect heater hose pipe at intake manifold and cylinder head.
87. Install both rocker covers. Use rocker cover gaskets which came with Goodwrench engine.
Refer to service manual for details of installation procedure (section 6A5).
88. Install throttle body heater pipe.
89. Install ignition module assembly with spark plug wires attached. Tighten bolts to 25 Nm (19 lb. ft.)
90. Install intake plenum with throttle body attached and new plenum gaskets. Connect coolant and vacuum hoses. Refer to service manual for cleaning and installation procedure.
91. Install alternator bracket.
92. Install engine lifting device and remove engine assembly from stand.
93. Install flywheel. Apply GM Thread Lock (or equivalent) to all flywheel bolts and tighten bolts to 70 Nm (52 lb. ft.).
94. Install engine assembly in vehicle.
95. Install upper engine/transaxle mounting bolts. Tighten bolts to 75 Nm (55 lb. ft.).
96. Remove support at transaxle.
97. Remove engine lifting device.
98. Raise vehicle.
99. Install lower engine/transaxle bolts. Tighten bolts to 75 Nm (55 lb. ft.).
100. Install front engine mount nuts at frame. Tighten nuts to 45 Nm (34 lb. ft.).
101. Install transaxle support bracket bolts at transaxle.
Tighten rear bolts to 83 Nm (61 lb. ft.) and front bolts to 43 Nm (35 lb. ft.).
102. Install A/C compressor and mounting bolts. Refer to service manual for details of installation procedure (section 1 B).
103. Install torque convertor bolts. Tighten bolts to 60 Nm (44 lb. ft.).
104. Connect lower ground strap at transaxle.
105. Install starter.
106. Install flywheel cover. Tighten bolts to 10 Nm (89 lb. in.).
107. Install rear A/C compressor to starter pencil brace.
Refer to service manual for details on installation procedure (section 1 B).
108. Connect front exhaust pipe to manifold with new seal. Tighten bolts to 47 Nm (35 lb. ft.).
109. Install right-hand engine splash shield.
110. Install oil filter.
111. Lower vehicle.
112. Rotate engine to forward position (see step 10).
113. Connect oxygen sensor electrical connector.
114. Connect vacuum modulator line at transaxle.
115. Connect upper electrical grounds at transaxle.
116. Connect fuel lines at rail and bracket.
117. Connect upper engine wiring harness connectors and install wiring harness tie straps.
118. Install power steering pump. Tighten bolts to 27.5 Nm (20.5 lb. ft.).
119. Install throttle control cable bracket at plenum.
120. Install brake vacuum pipe at plenum and booster.
121. Install throttle control cables at throttle body.
122. Install alternator assembly.
123. Install MAP sensor and bracket.
124. Rotate engine to normal position and connect both engine mounts.
125. Install serpentine belt.
126. Install ECM cover.
127. Install exhaust crossover pipe. Tighten bolts to 25 N m (18 lb. ft.).
128. Connect throttle valve cable to transmission.
129. Connect upper and lower radiator hoses and heater hoses.
130. Install coolant recovery tank.
131. Install air cleaner and duct assembly.
132. Install hood.
133. Fill engine to appropriate level with new engine oil (approx. 4.5 qts.).
134. Reconnect battery cables.
135. Refill coolant system with new coolant. Add two (2) engine cooling system sealer pellets to radiator. Coolant must be mixed with an equal amount of water and coolant (50/50) to provide proper protection
136. Start engine and verify no fluid leaks.
137. Reset radio, clock, etc.
PROCEDURE FOR LUMINA APV'S
1. Disconnect battery cables. Be certain to note all radio settings, etc. prior to disconnecting.
2. Remove air cleaner assembly.
3. Drain cooling system.
4. Discharge/recover A/C system refrigerant. Refer to service manual for discharging A/C system (section 1 B).
5. Disconnect ECM harness at ECM and push harness through to engine compartment.
6. Remove necessary ECM harness fasteners to chassis and lay harness on engine assembly.
7. Remove throttle and throttle valve cable at TBI unit.
8. Disconnect fuel lines at TBI unit.
9. Remove transaxle shift linkage and bracket at transaxle.
10. Remove radiator and heater hoses at engine side.
11. Remove left-hand engine compartment crossbrace with washer reservoir assembly.
12. Remove engine wiring harness from block connector at left hood hinges and lay on engine assembly.
13. Remove engine torque strut to engine.
14. Raise vehicle.
15. Drain oil and remove filter.
16. Remove transaxle cooler lines at radiator.
17. Remove front right-hand and left-hand wheel locks, if equipped.
18. Remove front right-hand and left-hand tire and wheel assemblies.
19. Remove right-hand and left-hand tie rod ends to steering knuckle.
20. Remove right-hand and left-hand ball joints from steering knuckles. Refer to service manual for details of removal procedure (section 4D).
21. Remove right-hand and left-hand axle shaft from transaxle. Refer to service manual for details of removal procedure (section 4D).
22. Position axle/hub assembly up and wire to strut.
23. Remove intermediate steering shaft pinch bolt and shaft from steering gear.
24. Remove A/C compressor suction/discharge fitting at rear of compressor and cover to prevent damage/ contamination.
25. Remove starter wiring at starter assembly and remove engine ground.
26. Remove starter assembly and A/C compressor brace from engine.
27. Remove transaxle convertor shields.
28. Remove flywheel to convertor attaching bolts.
29. Remove exhaust pipe to exhaust manifold bolts and springs.
30. Remove right-hand inner fender shield and power steering hose retaining clamps at right-hand frame rail.
31. Remove engine ground strap to lower tie bar. Refer to service manual (section 6D5, Figure 9).
32. Remove engine mount to frame retaining bolts and washers.
33. Lower vehicle and support engine/transaxle for removal from vehicle onto stand J 36295.
34. Remove engine/transaxle frame to body retaining bolts and raise vehicle.
35. Remove serpentine belt guide cover and belt.
36. Remove alternator wiring, generator and bracket.
37. Remove power steering pump and lines from engine. Wire pump assembly and lines to frame.
Notice: Do not disconnect lines from pump.
38. Remove A/C compressor support brace and compressor assembly.
39. Remove front and rear coolant by-pass pipes from engine.
40. Remove water pump from front cover.
41. Remove spark plug wiring at spark plugs and remove spark plug wire routing retainers.
42. Remove TBI wiring, hoses, and TBI unit from intake manifold.
43. Remove engine wiring harness from engine.
44. Remove distributor retainer and distributor assembly from engine.
45. Remove both rocker arm covers.
46. Remove intake manifold assembly.
47. Remove serpentine belt tensioner from engine front cover.
48. Remove torque strut and A/C compressor mounting bracket.
49. Remove torsional damper bolt from crankshaft.
50. Remove torsional damper from crankshaft using J 24420-B.
51. Remove exhaust crossover pipe from both engine exhaust manifolds.
52. Remove engine exhaust manifolds.
53. Remove ignition coil and bracket.
54. Remove electronic vacuum regulator valve (EVRV) and bracket.
55. Remove oil filter adaptor and sensor assembly.
56. Remove engine spark control (ESC) knock sensor.
57. Remove engine coolant sensor from cylinder head.
58. Remove engine to transaxle bracket bolts and bracket.
59. Remove engine block heater, if equipped.
60. Remove engine to transaxle retaining bolts.
61. Separate engine from transaxle.
62. Remove engine mount bracket bolts at engine block.
63. Remove flywheel from engine.
64. Clean all gasket surfaces on new engine.
65. Install flywheel to new engine, apply GM Thread
Lock to all flywheel bolts and tighten bolts to 70 Nm (52 lb. ft.)
66. Install engine to front mount bracket. Tighten three front bolts to 80 Nm (59 lb. ft.) and one side bolt to 110 Nm (80 lb. ft.).
67. Install engine to transaxle retaining bolts. Tighten bolts to 75 Nm (55 lb. ft.).
68. Install engine to transaxle bracket. Refer to service manual for details of installation procedure (section 6A).
69. Install new engine oil level indicator (dipstick) tube to new engine (tube packaged loose with Goodwrench engine).
70. Install new engine oil level indicator (dipstick) into indicator tube (indicator packaged loose with Goodwrench engine).
71. Install engine block heater, if equipped.
72. Install engine coolant sensor.
73. Install ESC knock sensor. Tighten sensor to 19 Nm (14 lb. ft.).
Notice: Be sure threads are clean.
74. Install oil filter adaptor, including oil pressure sensor and new adaptor gasket. Tighten connector through adaptor to 39 Nm (29 lb. ft.).
75. Install EVRV and bracket to cylinder head.
76. Install ignition coil and bracket to cylinder head.
77. Install both engine exhaust manifolds and new exhaust manifold gaskets. Refer to service manual for details of installation procedure (section 6A4).
78. Install exhaust crossover pipe. Tighten nuts to 25 Nm (18 lb. ft.).
79. Install torque strut/air conditioning compressor mounting bracket on engine.
80. Install torsional damper to crankshaft. Refer to service manual for details of installation procedure (section 6A4).
81. Install serpentine belt tensioner assembly to front cover. Refer to service manual for details of installation procedure (section 6A4).
82. Install intake manifold assembly and new intake manifold gasket. Refer to service manual for details of installation procedure (section 6A4).
83. Install both rocker arm covers. Use rocker cover gaskets which came with Goodwrench engine. Refer to service manual for details of installation procedure (section 6A4).
84. Install distributor assembly and new seal 0-Ring. Refer to service manual for details of installation procedure (section 6D4).
Notice: Do not tighten retaining bolt at this time.
85. Install TBI unit and new gasket. Refer to service manual for details of installation procedure (section 6E2).
86. Install engine wiring harness and vacuum harness.
87. Install spark plugs and attach spark plug wires.
88. Install water pump and new gasket. Tighten bolts to 10 Nm (89 lb. in.).
89. Install front and rear coolant by-pass pipes.
90. Install A/C compressor assembly and support brace. Refer to service manual for details of installation procedure (section 1 B).
91. Install power steering pump and lines. Refer to service manual for details of installation procedure (section 3B1).
92. Install alternator assembly, brace and wiring.
93. Install serpentine drive belt and cover.
94. Install engine/transaxle on frame into vehicle by raising stand J 36295 up to vehicle. Tighten bolts to 140 N m (103 lb. ft.).
95. Install power steering line retaining clamps and right-hand inner fender shield.
96. Install exhaust pipe to exhaust manifold bolts and springs, and new exhaust manifold pipe seal. Refer to service manual for details of installation procedure (section 6F).
97. Install flywheel to convertor attaching bolts. Tighten bolts to 60 Nm (44 lb. ft.).
98. Install convertor cover.
99. Install starter assembly including all wiring and A/C compressor brace.
100. Install A/C compressor suction/discharge fitting to compressor.
101. Install intermediate steering shaft to gear and pinch bolt.
102. Install right-hand and left-hand axle assemblies to transaxle.
103. Install right-hand and left-hand steering knuckle- to-ball joint pinch bolt. Refer to service manual for details of installation procedure (section 4D).
104. Install right-hand and left-hand tie rod ends to steering knuckle. Refer to service manual for details of installation procedure (section 4D).
105. Install right-hand and left-hand tire and wheel assemblies (with wheel locks if equipped).
106. Install ground strap at lower tie bar from engine harness.
107. Install transaxle cooler lines at radiator.
108. Lower vehicle.
109. Install engine torque strut to engine.
110. Install engine wiring harness to block connector at left hood hinge.
111. Install left-hand engine compartment crossbrace with washer reservoir.
112. Install radiator and heater hoses to engine.
113. Install transaxle shift bracket and linkage to transaxle.
114. Install throttle and throttle valve cables to TBI unit.
115. Install fuel lines at TBI unit.
116. Install necessary ECM harness fasteners to chassis.
117. Install engine harness through cowl and connect at ECM.
118. Refill coolant system with new coolant. Add two (2) engine cooling system sealer pellets to radiator. Coolant must be mixed with an equal amount of water and coolant (50/50) to provide proper protection.
119. Fill engine to appropriate level with new engine oil.
120. Install air cleaner assembly.
121. Reconnect battery cables.
122. Check engine timing and tighten distributor retainer.
123. Check and adjust front suspension toe to specifications.
124. Recharge A/C system. Refer to service manual for recharging procedure (section 1 B).
125. Start engine and verify no fluid leaks.
126. Reset radio, clock, etc.
CLAIM INFORMATION
Submit a claim with the information indicated below:
FAILED PARTS CC-FC LABOR LABOR REPAIR PERFORMED PC PART NO. ALLOW OP HRS ---------------- -- -------- ----- ----- ------ ----- Install New Partial Engine - Lumina Coupe Or ** Sedan Built Prior 21 10089656 * SP-95 T3321 10.3 To VIN L9124965 Or VIN L1114223 Install New Engine Assy. - Lumina Coupe Or ** Sedan Built After 21 12513153 * SP-95 T3323 8.5 VIN L9124965 Or VIN L1114223 Install New Engine ** - Lumina APV 21 12513152 * SP-95 T3322 8.2 Reimbursement For Prior Piston - -- -- SP-95 T3324 -- Scuffing Repair
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30% of all parts required for the repair.
** The following add times may be applied for as required.
For T3321 PARTIAL ENGINE (Lumina Coupes And Sedans Built Prior To VIN L9124965 Or VIN L1114223):
Vehicles With Air Conditioning (Recharge) 0.4 Hrs. Clean Parts On Vehicles Over 30,000 Miles 0.8 Hrs. (If Necessary) Vehicles With Block Heater 0.1 Hrs. Recondition All Valves 2.0 Hrs.
For T3323 ENGINE ASSEMBLY (Lumina Coupes And Sedans built After To VIN L9124965 Or VIN L1114223):
Vehicles with Air Conditioning 0.4 Hrs. Clean parts On Vehicles Over 30,000 Miles 0.5 Hrs. (If Necessary) Vehicles With Block Heater 0.1 Hrs.
For T3322 ENGINE ASSEMBLY (Lumina APV):
Vehicles With Locking Wheel Covers/Nuts 0.1 Hrs. Vehicles With Air Conditioning 0.9 Hrs. Clean Parts On Vehicles Over 30,000 Miles 0.5 Hrs. (If Necessary) Vehicles With Block Heater 0.1 Hrs.
Refer to the Chevrolet Claims Processing Manual for details on warranty claim submission.
Dear Chevrolet Owner:
As the owner of a 1990 Lumina Coupe, Sedan, or APV model vehicle equipped with a 3.1 L engine, your continued satisfaction with our products is of utmost concern to us. Your vehicle was provided with new vehicle warranties which covers certain parts for a specified period. These warranties are of considerable value to you if you experience problems with your vehicle.
This letter is intended to make you aware that some 1990 Lumina Coupe, Sedan, or APV model vehicles built with 3.1 L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking noise at low ambient temperatures. This condition will not lead to engine failure.
In addition to your normal warranty coverage, GM is providing special coverage if your vehicle is affected by the described condition. If the above-mentioned condition occurs within six years from the date your vehicle was originally placed in service, or 72,000 miles, whichever occurs first, your vehicle will be repaired free of charge.
If you have already experienced this condition, and you have paid to have it repaired, you may contact your Chevrolet dealer to seek reimbursement. Connecticut, Virginia, and Wisconsin residents must write to Chevrolet Motor Division, Customer Assistance Center, P. 0. Box 7047, Troy, MI 48007-7047 for reimbursement. In either situation, please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by August 31, 1994 (this time limitation for presenting the original paid receipt may be longer depending upon the law in your state).
If your vehicle has not experienced this condition, do nothing at this time. Just place this letter in the glove box with your owner's manual and other warranty information, in case you should need to take advantage of this policy in the future. If you sell or trade your car anytime during this additional warranty period, please leave the information with the owner's manual so the new owner will be aware of eligibility during the unexpired portion of this coverage.
Should you have any questions regarding this additional warranty period, please feel free to call us. Our toll free number is 1-800-222-1020, and one of our Customer Assistance Specialists will be happy to answer any questions you may have.
We are very pleased to have you as a customer and hope you will choose Chevrolet again when you make your next vehicle purchase.
Chevrolet Motor Division GENERAL MOTORS CORPORATION
INSTRUCTIONS
1 R.O. # & DATE The dealership should enter the repair order number and date of the reimbursement request.
2 WORK PERFORMED Date owner had work performed. DATE (MONTH, DAY)
3 VEHICLE VIN involved. IDENTIFICATION NUMBER
4 MILEAGE Enter mileage at time of repair. (If not available, enter "0".) Should not be greater than 72,000 miles.
5 CC/FC Code is preprinted on form.
6 LABOR OPERATION Labor Operation is preprinted on form.
7 & 8 SUBLET DMN & Enter exact amount of reimbursement. No LINE TOTAL deductible will be taken. (Do not enter parts or labor hours on claim).
9 AUTH CODE If the total exceeds $1,000, the owner should mail the original Repair Order, proof of ownership and proof of payment to Chevrolet Customer Assistance, P.O. box 7047, Troy, MI 48007-7047.
10 REQUESTED Dealer Service Manager enters the amount REIMBURSEMENT determined from owner supplied invoices or paid receipts, which are covered.
11 APPROVED AMOUNT If the total exceeds $1,000, the owner should mail the original Repair Order, proof of ownership and proof of payment to Chevrolet Customer Assistance, P.O. Box 7047, Troy MI 48007-7047.
12 740 STAMP See Item #11 to determine need for author- ization.
13 DEALER REFERENCE A Enter Document Number & Line Number on INFORMATION which claim was submitted.
B Enter Claim Memo Number and Date when claim is credited.
C Enter number of dealer check to owner, if applicable. Date copy of check was attached to OWNER REQUEST FOR REIMBURSEMENT file.
14 OWNER INFORMATION Must include telephone number
15 DEALER INFORMATION Includes Dealer Code, Dealer Name, Service Manager's Signature and social security number. To be completed by Service Manager.
16 EXPLAIN Should the dealer Service Manager determine after review of owner's invoices/receipts, that the reimbursement case is not eligible; Service Manager should write reason on worksheet, explain to owner, and place a copy of the worksheet in the vehicle history file.
17 The dealer is then to issue the owner a check for the reimbursement in the approved amount. A copy of the check issued to the owner is to be attached to the dealer's file copy of the request and retained for 24 months from date of credit.
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.
