3.4L TWIN DOHC V6 ENGINE EXCHANGE PROGRAM

SUBJECT: 3.4L TWIN DUAL CAM V6 ENGINE EXCHANGE PROGRAM

VEHICLES AFFECTED: 1991-92 "W" CAR -----------------------------------------------------------------------------

THIS BULLETIN HAS BEEN REVISED TO EXTEND THE ENGINE EXCHANGE PROGRAM TO THE END OF THE 1992 MODEL YEAR (AND CLARIFY THE TEXT REGARDING SAME)

To gain needed product feedback on the new 1991-92 3.4L Twin Dual Cam V6 engine, an exchange program is now in effect and will continue until the end of the 1992 model year.

This exchange program will be administered by the Technical Assistance Centre (TAC).

The following explains all requirements regarding serviceable and non- serviceable items, warranty claims processing procedures and shipping instructions.

The information should be filed in the "Special Exchange Policy Procedures" manual.

If your dealership receives a comment on this 1991-92 engine, follow the procedure listed below. Your cooperation will greatly improve the effectiveness of the program.

If any internal components require replacement, the engine must be exchanged.

THE FOLLOWING COMPONENTS ARE NOT TO BE REMOVED

Cylinder Case Cam Sprocket Oil Seals Cam Cover Cylinder Heads. Front Cover Cylinder Head Gaskets Oil Pump Lower Intake Harmonic Balancer Crankshaft and Pulley Crank Sprocket Timing Chain Camshafts Piston Assembly Cam Carriers (Pistons, Rods, Rings) Windage Tray Oil Distribution Cover Cam Belt Drive System and Related Components

A. ENGINE COMPONENTS WHICH MAY BE SERVICED (without exchange): ---------------------------------------------------------------- NOTE: Any deficient engine component on the following list should be repaired according to Service Procedures in the 1991 - 92 Service Manuals.

1. Brackets: Rear lift and torque strut bracket (Automatic and Manual), and accelerator cable bracket.

2. Water Pump: Water pump and related gaskets, water outlet, thermostat, water inlet and gasket, coolant bypass pipe and hose.

3. Vacuum T@: PCV hoses and related components. Transmission Modulator Pipe

4. Ignition: Spark plugs, left and right hand wiring harnesses, ignition coil pack.

5. Electrical: Knock sensor, coolant level sensor, coolant Components temperature sensor, crank timing sensor, MAP sensor, oil pressure sensor, oxygen sensor, TPS sensor and IAC valve.

6. Upper Intake Plenum and related 0-ring seal, fuel rail and injectors, fuel lines, fuel pressure regulator and hose, EGR tube, EGR valve and mounting related parts.

7. Injector Wiring Harness

8. Block Heater (if applicable)

9. Flywheel Assembly

10. Clutch and pressure Plate Assembly

11. Exhaust Manifolds and Related Gaskets, A.I.R. Pipes and Check Valves.

12. Oil Pan, Oil Dipstick and Tube, Oil Cap, Oil Filter and Oil Cooler.

13. Complete Accessory Drive and Supporting Brackets, to include Starter, Generator, A/C Compressor, Power Steering Pump, and All Attaching Parts.

14. Cam Drive Plastic Covers

15. Plastic Injector Cover

16. Starter Motor

B. ENGINE EXCHANGE: ------------------- Any deficient engine component not included in paragraph (A.) above may necessitate an exchange engine.

C. EXCHANGE PROCEDURE: ---------------------- Once the above preliminary diagnosis is made and an exchange unit is deemed necessary, call TAC Passenger Car Chassis Group.

The TAC group will arrange to ship an exchange unit to your dealership and provide your dealership with a TAC reference number. This number must be written on the return engine intake plenum chamber, before returning the unit.

To increase the effectiveness of the program, the concerned unit must be returned immediately (not later than 1 week after date of -------------------------- receipt of replacement unit). -----------------------------

FAILURE TO RETURN THE CONCERNED UNIT WILL RESULT IN THE DEALERSHIP

BEING BILLED THE VALUE OF AN EXCHANGE ENGINE.

All procedural steps must be followed to ensure that your dealership is not billed for this engine.

The removed unit must be returned complete as removed from the vehicle in the container provided, without examination of the unit other than as described in Paragraph A above. Engine dress on the removed unit must remain same as replacement engine was shipped (i.e. manifolds, throttle body, etc.). Dealerships returning units that have been 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 minimum quantity of oil; add oil per specifications.

The exchange unit will have an envelope attached to it. This envelope will contain:

- Plastic bottles (for oil sample and coolant sample) - Return shipping label (freight is prepaid). - Leak identification charts.

NOTE: An exchange engine will be shipped within twenty-four (24) hours or one working day. The engine plant will make every effort to assure delivery to dealer within forty-eight (48) hours or two working days.

D. PREPARATION FOR SHIPPING: ------------------------------ Visually check to establish that all fluid levels are within the normal operating range. If not, drain and measure the oil and coolant from the concerned unit. Capture a supply of oil and coolant samples in plastic bottles. Record the oil and coolant measurement results on the repair order. REPLACE THE DRAIN PLUG. -----------------------

Remove engine assembly as outlined in the 1991 - 92 Service Manuals. Remove all plastic shipping plugs and covers from the exchange unit and install them on the removed unit.

If engine leaks, mark leak area on engine. Mark area of leakage on illustrations, provided with exchange unit, with red pen. Write the TAC reference number on the leak identification forms.

Repack the removed unit into the original shipping container.

Place oil and coolant sample bottles, leak identification charts and copy of repair order in original envelope and attach to original engine.

E. SHIPPING INSTRUCTIONS ------------------------- Place the shipping label over the original label on the original shipping container.

The Bill of Lading and Custom Papers provided with the exchange engine are the only documents 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 engine 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 returning the engine.

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

St. Catharines Engine Plant 570 Glendale Ave. St. Catharines, Ontario L2R 7B3

Attn: Z34 Engine Exchange Program Quality Assurance Department

To increase 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 $3,000.00 for the unit furnished, plus an Administrative Charge.

F. WARRANTY CLAIMS PROCESSING PROCEDURE ---------------------------------------- Upon completion of the repair, a warranty claim is to be submitted to the Marketing Division.

Labour Operation Part Labour Other Number Description Allowance Hours Hours ---------- ----------------- ---------- ------ ------- T1701 Replace Engine Assembly (With Auto Trans.) $ 492.64 6.9 Hours 0.2 Hour

(With Manual Trans.) $ 492.64 7.9 Hours 0.2 Hour

Add Time: With Air Conditioning (With Auto Trans.) 0.8 Hours

With Air Conditioning (With Manual Trans.) 1.0 Hour

* Administrative Allowance

** The amount identified in the "Part Allowance" column above represents 30% of dealer net price of the difference between the current CANSPO Dealer Net price less the engine return credit (Core Allowance) for parts that were furnished by the St. Catharines Engine Plant. This amount 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 YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IT YOU HAVE ANY QUESTIONS REGARDING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT THE TECHNICAL ASSISTANCE NETWORK .

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.