SPECIAL POLICY: ADJ. 3.1L ENGINE PISTON PLATING WEAR
ADJUSTMENT 3.1L ENGINE PISTON PLATING WEAR
MODELS: 1989-91 Buick Regal, 1990 Chevrolet Lumina and Lumina APV, 1989 Oldsmobile Cutlass Supreme and 1990 Pontiac Trans Sport with 3.1L engine
TO ALL GENERAL MOTORS DEALERS:
General Motors of Canada has determined that some 1989-1991 Buick Regal, 1990 Pontiac Trans Sport, 1989 Oldsmobile Cutlass Supreme, and 1990 Chevrolet Lumina 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
Engine Beginning Through & Year Make/Model VIN Code VIN Including ------------------------------------------------------------------------- 1989 Buick Regal T S.O.P. E.O.P. 1990 Buick Regal T. S.O.P. E.O.P. 1991 Buick Regal T S.O.P. 429877 1990 Chevrolet Lumina T S.O.P. E.O.P. 1990 Chevrolet Lumina APV D S.O.P. E.O.P. 1989 Oldsmobile Cutlass Supreme T S.O.P. E.O.P. 1990 Pontiac Trans Sport D S.O.P. E.O.P.
SPECIAL POLICY ADJUSTMENT
This Special Policy covers the condition described above for a period of six years or 120,000 km, 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.
OWNER NOTIFICATION
Owners will be notified of this special policy on their vehicle by General Motors of Canada Limited (see copy of the owner letter included with this bulletin).
OWNER REIMBURSEMENT
Customer claims for reimbursement 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 September 30, 1994. Repairs must have occurred within 6 years of the date the vehicle was originally placed in service, or 120,000 km, 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 as a Net Item Dollar Amount on a Warranty Claim.
PARTS INFORMATION
Parts required to complete the service procedure are to be obtained from General Motors Service Parts Operation (GMSPO).
Part Quantity/ Number Description Vehicle Application ------------------------------------------------------------------------- 12513153 Targetmaster Engine 1 All affected Regals, Cutlass Supremes, & Luminas (except 1990 Chevrolet Luminas with VINs up to L9124965 and L1114223 with 3.1L (LH0) engine.
" 10182374 Water Pump Gasket 1 12337894 Oil Filter Adapt. Gasket 1 "
10104430 Plenum Gasket Kit 1 "
14100625 Exhaust Manifold Gasket - Left-Hand 1 "
10078991 Exhaust Manifold Gasket - Right-Hand 1 " 10094825 Seal, Exhaust Manifold Pipe 1 " 993088 Engine Coolant (1 Liter) 6 "
25010908 Oil Filter (PF5 1) 1 "
993194 Engine Oil, 5W-30 (4 Liters w/filter) 1 " 3634621 Engine Coolant System Sealer 2 pellets " (Package of 6)
10228009 Engine Oil Level Indicator 1 "
10228010 Engine Oil Level Indicator Tube 1 "
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12513152 Targetmaster Engine 1 All affected 1990 Pontiac Trans Sports and Chevrolet Lumina APV with 3.1L (LG6) engine. 12520756 Intake Manifold Gasket Kit 1 "
14092220 Throttle Body Gasket 1 "
1977935 Distributor O-Ring 1 "
10182374 Water Pump Gasket 1 "
12337894 Oil Filter Adapt Gasket 1 "
10094825 Seal, Exhaust Manifold Pipe 1 "
993088 Engine Coolant (1 Liter) 6 "
993194 Engine Oil, 5W-30 (4 Liters w/filter) 1 "
25010908 Oil Filter (PF5 1) 1 "
3634621 Engine Coolant System Sealer 2 pellets " (Package of 6)
10230424 Engine Oil Level Indicator 1 "
10182360 Engine Oil Level Indicator Tube 1 "
****************************************************************************
10089656 Partial Engine 1 All affected 1990 Chevrolet Luminas from start of pro- duction up to VINs L9124964 and L1114222 with 3.1L (LH0) engine.
12337894 Oil Filter Adapter Gasket 1 "
10094825 Seal, Exhaust Manifold Pipe 1 "
12511885 Gasket Kit (Gaskets for: Intake 1 " Manifold, Exhaust Manifold and Intake Plenum)
10189276 Front Cover Gasket 1 "
10151654 Oil Pan Gasket 1 "
10111769 Crankshaft Front Oil Seal 1 "
993088 Engine Coolant (1 Liter) 6 liters "
25010908 Oil Filter (PF5 1) 1 "
993194 Engine Oil, 5W-30 (4 Liters w/filter) 4 liters "
3634621 Engine Coolant System Sealer 2 pellets " (Package of 6)
**************************************************************************** SERVICE PROCEDURE ----------------- SERVICE PROCEDURE FOR 'W' CAR PARTIAL ENGINE -------------------------------------------- Note: All radio settings, clock, etc.
1. Disconnect battery cables.
2. Remove hood assembly.
3. Remove air cleaner and duct assembly.
4. Drain engine coolant.
5. Disconnect upper and lower rad. hoses, heater hoses and 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. Refer to Service Manual for rotating and locking engine into position, Figure 9 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 intake 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 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 converter 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 generator 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 body 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 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 adapter.
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 the 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 (P/N 10089656).
71. Install the engine oil indicator tube and engine oil level indicator on new engine.
72. Install transaxle support bracket.
73. Install ESC knock sensor. Tighten sensor to 19 N.m (14 lb. ft.). Note: Be sure threads are clean.
74. Install crankshaft sensor. Refer to Service Manual for inspection and installation procedure, Section 6E3-C4.
75. Install oil filter adapter, including oil pressure sensor and new adapter gasket (P/N 12337894). Tighten connector through adapter to 39 N.m (29 lb. ft.).
76. Install camshaft. Refer to Service Manual for installation procedure, Section 6A5.
77. Install oil pump driveshaft extension assembly. Tighten bolt to 34 N.m (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 N.m (15 lb. ft.).
80. Install timing chain cover, new gasket (P/N 10189276) and new crankshaft front oil seal (P/N 10111769). Refer to Service Manual for cleaning and installation procedure, Section 6A5.
81. Install oil pump and shaft. Tighten bolt to 41 N.m (30 lb. ft.).
82. Install oil pan and new oil pan gasket (P/N 10151654). Refer to Service Manual for cleaning and installation procedure (Section 6A5).
83. Install front engine mount bracket. Tighten bolts to 85 N.m (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 N.m (40 lb. ft.).
86. Install upper engine wiring harness.
87. Install cylinder heads and new head gaskets (kit P/N 12511885). Refer to Service Manual for cleaning and installation procedure, Section 6A5.
88. Install exhaust manifolds and new gaskets (kit P/N 12511885). 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 (kit P/N 12511885). 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 covers and new gaskets (kit P/N 12511885). Refer to Service Manual for details of installation procedure, Section 6A5.
93. Install throttle body heater pipe.
94. Install ignition module assembly with spark plugs wires attached. Tighten bolts to 25 N.m (19 lb. ft.).
95. Install intake plenum with throttle body attached and new plenum gaskets (kit P/N 12511885). Connect coolant and vacuum hoses. Refer to Service Manual for cleaning and installation procedure.
96. Install generator mounting bracket.
97. Install engine lifting device and remove engine assembly from stand.
98. Install flywheel. Apply GM thread lock to all flywheel bolts and tighten bolts to 70 N.m (52 lb. ft.).
99. Install engine assembly in vehicle.
100. Install upper engine/transaxle bolts. Tighten bolts to 75 N.m (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 N.m (55 lb. ft.).
105. Install front engine mount nuts at frame. Tighten nuts to 45 N.m (34 lb. ft.).
106. Install transaxle support bracket bolts at transaxle. Tighten rear bolts to 83 N.m (61 lb. ft.) and front bolts to 43 N.m (35 lb. ft.).
107. Install A/C compressor and mounting bolts. Refer to Service Manual details of installation procedure, Section IB.
108. Install torque converter bolts. Tighten bolts to 60 N.m (44 lb. ft.).
109. Connect lower ground strap at transaxle.
110. Install starter.
111. Install flywheel cover. Tighten bolts to 10 N.m (89 lb. in.).
112. Install rear A/C compressor to starter pencil brace. Refer to Service Manual for details on installation procedure, Section 1B.
113. Connect front exhaust pipe at manifold with new seal (P/N 10094825). Tighten bolts to 47 N.m (35 lb. ft.).
114. Install right-hand engine splash shield.
115. Install new oil filter (P/N 25010908).
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 N.m (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 generator assembly.
128. Install MAP sensor and bracket.
129. Rotate engine on normal position and connect both engine mounts.
130. Install serpentine belt.
131. Install ECM cover.
132. Install exhaust crossover pipe. Tighten bolts to 25 N.m (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. Install engine to appropriate level with new engine oil (P/N 993194 [4 liters]).
139. Reconnect battery cables.
140. Refill coolant system with new coolant (P/N 993088 [6 liters]). Add two (2) engine cooling system sealer pellets from package, P/N 3634621, to the radiator. Coolant must be mixed with equal amount of water (50/50) to provide proper protection.
141. Start engine and verify no fluid leaks.
142. Reset radio, clock, etc.
SERVICE PROCEDURE FOR APVs AND TRANS SPORTS TARGETMASTER ENGINE REPLACEMENT
Note All radio settings, clock, etc.
1. Disconnect battery cables.
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 1B.
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-hand hinges and lay on engine assembly.
13. Remove engine torque strut to engine.
14. Raise vehicle. Drain oil and remove filter.
15. Remove transaxle cooler lines at radiator.
16. Remove front left-hand and right-hand wheel locks, if equipped.
17. Remove front left-hand and right-hand tire and wheel assemblies.
18. Remove left-hand and right-hand tie rod ends to steering knuckle.
19. Remove left-hand and right-hand control arm ball joints from steering knuckles. Refer to Service Manual for details of removal procedure, Section 3C.
20. Remove left-hand and right-hand axle shaft from transaxle. Refer to Service Manual for details of removal procedure, Section 4D.
21. Position axle/hub assembly up and wire to strut.
22. Remove intermediate steering shaft pinch bolt and shaft from steering gear.
23. Remove A/C compressor suction/discharge fitting at rear of compressor and cover to prevent damage/contamination.
24. Remove starter wiring at starter assembly and remove engine ground.
25. Remove starter assembly and A/C compressor brace from engine.
26. Remove transaxle converter shields.
27. Remove flywheel to converter attaching bolts.
28. Remove exhaust pipe to exhaust manifold bolts and springs.
29. Remove right-hand inner fender shield and power steering hose retaining clamps at right- hand frame rail.
30. Remove engine ground strap to lower tie bar. Refer to Service Manual, Figure 9 in Section 6D5.
31. Remove engine mount to frame retaining bolts and washers.
32. Lower vehicle and support engine/transaxle for removal from vehicle onto stand J-36295.
33. Remove engine/transaxle frame to body retaining bolts and raise vehicle.
34. Remove serpentine belt guide cover and belt.
35. Remove alternator wiring, generator and support bracket.
36. Remove power steering pump and lines from engine. Wire pump assembly and lines to frame. Note: Do not disconnect lines from pump.
37. Remove A/C compressor support brace and compressor assembly.
38. Remove front and rear coolant by-pass pipes from engine.
39. Remove water pump from front cover.
40. Remove spark plug wiring at spark plugs and remove spark plug wire routing retainers.
41. Remove TBI wiring, hoses and TBI unit from intake manifold.
42. Remove engine wiring harness from engine.
43. Remove distributor retainer and distributor assembly from engine.
44. Remove both rocker arm covers.
45. Remove intake manifold assembly.
46. Remove serpentine belt tensioner from engine front cover.
47. Remove torque strut and A/C compressor mounting bracket.
48. Remove torsional damper bolt from crankshaft.
49. Remove torsional damper from crankshaft using J24420-B.
50. Remove exhaust crossover pipe from both engine exhaust manifolds.
51. Remove engine exhaust manifolds.
52. Remove ignition coil and bracket.
53. Remove Electronic Vacuum Regulator Valve (EVRV) and bracket.
54. Remove oil filter adapter and sensor assembly.
55. Remove Electronic Spark Control (ESC) knock sensor.
56. Remove engine coolant sensor from cylinder head.
57. Remove engine to transaxle bracket bolts and bracket.
58. Remove engine block heater, if equipped.
59. Remove engine to transaxle retaining bolts.
60. Separate engine from transaxle.
61. Remove engine front mount bracket bolts at engine block.
62. Remove flywheel from engine.
63. Clean all gasket surfaces on new engine (P/N 12513152).
64. Install flywheel to new engine, apply GM thread lock to all flywheel bolts and tighten bolts to 70 N.m (52 lb. ft.).
65. Install engine to front mount bracket. Tighten three front bolts to 80 N.m (59 lb. ft.) and one side bolt to 110 N. m (80 lb. ft.).
66. Install engine to transaxle retaining bolts. Tighten bolts to 75 N.m (55 lb. ft.).
67. Install engine to transaxle bracket. Refer to Service Manual for details of installation procedure, Section 6A.
68. Install new engine oil level indicator (dipstick) tube to new engine (P/N 10182360).
69. Install new engine oil level indicator (dipstick) into indicator tube (P/N 10230424).
70. Install engine block heater, if equipped.
71. Install engine coolant sensor.
72. Install ESC knock sensor. Tighten sensor to 19 N.m (14 lb. ft.). Note: Be sure threads are clean.
73. Install oil filter adapter, including oil pressure sensor and new adapter gasket (P/N 12337894). Tighten connector through adapter to 39 N.m (29 lb. ft.).
74. Install EVRV and bracket to cylinder head.
75. Install ignition coil and bracket to cylinder head.
76. Install both engine exhaust manifolds and new exhaust manifold gaskets. Refer to Service Manual for details of installation procedure, Section 6A4.
77. Install exhaust crossover pipe. Tighten nuts to 25 N.m (18 lb. ft.).
78. Install torque strut/air conditioning compressor mounting bracket on engine.
79. Install torsional damper to crankshaft. Refer to Service Manual for details of installation procedure, Section 6A4.
80. Install serpentine belt tensioner assembly to front cover. Refer to Service Manual for details of installation procedure, Section 6A4.
81. Install intake manifold assembly and new intake manifold gasket. Refer to Service Manual for details of installation procedure, Section 6A4.
82. Install both rocker arm covers. Use the rocker cover gaskets which came with Targetmaster engine. Refer to Service Manual for details of installation procedure, Section 6A4.
83. Install distributor assembly and new seal o-ring (P/N 1977935). Refer to Service Manual for details of installation procedure, Section 6D4. Note: Do not tighten retaining bolt at this time.
84. Install TBI unit and new gasket (P/N 14092220). Refer to Service Manual for details of installation procedure, Section 6E2.
85. Install engine wiring harness and vacuum harness.
86. Install spark plugs and spark plug wires.
87. Install water pump and new gasket (P/N 10182374). Tighten bolts to 10 N.m (89 lb. ft.).
88. Install front and rear coolant by-pass pipes.
89. Install A/C compressor assembly and support brace. Refer to Service Manual details of installation procedure, Section 1 B.
90. Install power steering pump and lines. Refer to Service Manual for details of installation procedure, Section 3B-1.
91. Install alternator assembly, brace and wiring.
92. Install serpentine drive belt and cover.
93. Install engine/transaxle on frame into vehicle by raising stand J-36295 up to vehicle. Tighten bolts to 140 N.m (103 lb. ft.).
94. Install power steering line retaining clamps and right-hand inner fender shield.
95. Install exhaust pipe to exhaust manifold bolts and springs and new exhaust manifold pipe seal (P/N 10094825). Refer to Service Manual for details of installation procedure, Section 6F.
96. Install flywheel to converter attaching bolts. Tighten bolts to 60 N.m (44 lb. ft.).
97. Install converter cover.
98. Install starter assembly including all wiring and A/C compressor brace.
99. Install A/C compressor suction/discharge fitting to compressor.
100. Install intermediate steering shaft to gear and pinch bolt.
101. Install right-hand and left-hand axle assemblies to transaxle.
102. Install left-hand and right-hand steering knuckle to ball joint pinch bolt. Refer to Service Manual for details of installation procedure (Section 4D).
103. Install left-hand and right-hand tie rod ends to steering knuckle. Refer to Service Manual for details of installation procedure (Section 4D).
104. Install left-hand and right-hand tire and wheel assemblies (with wheel locks, if equipped).
105. Install ground strap at lower tie bar from engine harness.
106. Install transaxle cooler lines at radiator.
107. Lower vehicle.
108. Install engine torque strut to engine.
109. Install engine wiring harness to block connector at left hood hinge.
110. Install left-hand engine compartment crossbrace with washer reservoir.
111. Install radiator and heater hoses to engine.
112. Install transaxle shift bracket and linkage to transaxle.
113. Install throttle and throttle valve cables to TBI unit.
114. Install fuel lines at TBI unit.
115. Install necessary ECM harness fasteners to chassis.
116. Install engine harness through cowl and connect at ECM.
117. Refill coolant system with new coolant (P/N 993088) 6 liters. Add two (2) engine cooling system sealer pellets from package (P/N 3634621) to the radiator. Coolant must be mixed with equal amounts of water (50150) to provide proper protection.
118. Install engine oil filter (P/N 25010908), engine oil (P/N 993194).
119. Install air cleaner assembly.
120. Reconnect battery cables.
121. Check engine timing and tighten distributor retainer.
122. Check and adjust toe.
123. Recharge A/C system. Refer to Service Manual for recharging procedure, Section 1B.
124. Start engine and verify no fluid leaks.
125. Reset radio, clock, etc.
SERVICE PROCEDURE FOR 'W' CAR TARGETMASTER ENGINE ------------------------------------------------- Note All radio settings, clock, etc.
1. Disconnect battery cables.
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 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 to pencil brace.
30. Remove flywheel cover.
31. Remove starter.
32. Disconnect lower ground strap at transaxle.
33. Remove torque converter bolts.
34. Remove A/C compressor mounting bolts and securely reposition compressor. Note: 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 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 adapter.
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 (P/N 12513153).
68. Install new engine oil level indicator (dipstick) tube on new engine (P/N 10228010).
69. Install new engine oil level indicator (dipstick) into indicator tube (P/N 10228009).
70. Install water pump and new gasket (P/N 10182374). Tighten bolts to 10 N.m (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 adapter, including oil pressure sensor and new adapter gasket (P/N 12337894). Tighten connector through adapter to 39 N.m (29 lb. ft.).
76. Install engine block heater, if equipped.
77. Install ESC knock sensor. Tighten sensor to 19 N.m (14 lb. ft.). Note: 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 N.m (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 N.m (40 lb. ft.).
82. Install upper engine wiring harness.
83. Install exhaust manifolds and new gaskets (P/N's R.H. 10078991, L.H. 14100625). 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 the rocker cover gaskets that came with Targetmaster 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 plugs wires attached. Tighten bolts to 25 N.m (19 lb. ft.).
90. Install intake plenum with throttle body attached and new plenum gaskets (P/N 10104430). 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 to all flywheel bolts and tighten bolts to 70 N.m (52 lb. ft.).
94. Install engine assembly in vehicle.
95. Install upper engine/transaxle mounting bolts. Tighten bolts to 75 N.m (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 N.m (55 lb. ft.).
100. Install front engine mount nuts at frame. Tighten nuts to 45 N.m (34 lb. ft.).
101. Install transaxle support bracket bolts at transaxle. Tighten rear bolts to 83 N.m (61 lb. ft.) and front bolts to 43 N.m (35 lb. ft.).
102. Install A/C compressor and mounting bolts. Refer to service manual for details on installation procedure, section IB.
103. Install torque converter bolts. Tighten bolts to 60 N.m (44 lb. ft.).
104. Connect lower ground strap at transaxle.
105. Install starter motor.
106. Install flywheel cover. Tighten bolts to 10 N.m (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 (P/N 10094825). Tighten bolts to 47 N.m (35 lb. ft.).
109. Install right-hand engine splash shield.
110. Install oil filter (P/N 25010908).
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 tie straps.
118. Install power steering pump mounting bolts. Tighten bolts to 27.5 N.m (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 (P/N 993194 - 4 liters).
134. Reconnect battery cables.
135. Refill coolant system with new coolant (P/N 993088 - 6 liters). Add two (2) engine cooling system sealer pellets from package, P/N 3634621, to the radiator. Coolant must be mixed with equal amount of water (50150) to provide proper protection.
136. Start engine and verify no fluid leaks.
137. Reset radio, clock, etc.
WARRANTY CLAIM INFORMATION
Use one of the applicable warranty labor operation numbers below:
Labor Parts Labor Repair Performed Operation Allowance Hours ---------------- Partial Engine Replacement Chevrolet Lumina* T-3321 ** 10.3 (model) Add Times as required: W/Air Conditioning (recharge) 0.4
Clean Parts on Vehicles over 50,000 km 0.8 (if necessary)
W/Block Heater 0.1
Recondition All Valves 2.0
Targetmaster Engine Replacement APV T-3322 ** 8.2 --- Add Times:
W/Locking Wheel Covers/Nuts 0.1
W/Air Conditioning 0.9
Clean Parts on Vehicles over 50,000 km 0.5 (if necessary)
W/Block Heater 0.1
Targetmaster Engine Replacement W T-3323 ** 8.5 - Add Times:
W/Air Conditioning 0.4
Clean Parts on Vehicles over 50,000 km 0.5 (if necessary)
W/Block Heater 0.1
Owner Reimbursement T-3324 0.2***
* Required only for 1990 Chevrolet Luminas with Vehicle Identification Numbers up to 124965 (Oshawa #1, Plant Code 9) and 114223 (Oshawa #2, Plant Code 1). For any 1990 Chevrolet Luminas with VIN greater than these, a Targetmaster engine replacement should be performed.
** Parts Allowance: Current Dealer Price, plus 30% handling allowance.
*** 0.2 hour dealer administrative allowance which is entered as other labour hours in the Warranty claim Submission. The appropriate customer reimbursement is to be entered in the claim submission with the current repair order date and the current odometer reading and as a net dollar amount.
Dear General Motors Customer:
As the owner of a Pontiac equipped with a 3.1L engine, your continued satisfaction with our products is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle 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 Pontiac Trans Sport vehicles built with 3. 1L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking (piston slap) 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 of the date your vehicle was originally placed in service, or 120,000 kilometers, whichever occurs first, your vehicle will be repaired free of charge.
If your vehicle has already experienced cold engine knocking noise, and you have paid to have it repaired, you should contact your GM dealer to seek reimbursement. Please provide your original paid receipts or invoices verifying the condition/repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by September 30, 1994.
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 the coverage.
We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule/Records and Warranty Booklet.
We regret any inconvenience that you may experience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
Dear General Motors Customer:
As the owner of a Chevrolet equipped with a 3.1L engine, your continued satisfaction with our products is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle 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 Chevrolet Lumina and Lumina APV vehicles built with 3.1L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking (piston slap) 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 of the date your vehicle was originally placed in service, or 120,000 kilometers, whichever occurs first, your vehicle will be repaired free of charge.
If your vehicle has already experienced cold engine knocking noise, and you have paid to have it repaired, you should contact your GM dealer to seek reimbursement. Please provide your original paid receipts or invoices verifying the condition/repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by September 30, 1994.
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 the coverage.
We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule/Records and Warranty Booklet.
We regret any inconvenience that you may experience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
Dear General Motors Customer:
As the owner of an Oldsmobile equipped with a 3. 1L engine, your continued satisfaction with our products is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle 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 1989 Oldsmobile Cutlass Supreme vehicles built with 3.1L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking (piston slap) 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 of the date your vehicle was originally placed in service, or 120,000 kilometers, whichever occurs first, your vehicle will be repaired free of charge.
If your vehicle has already experienced cold engine knocking noise, and you have paid to have it repaired, you should contact your GM dealer to seek reimbursement. Please provide your original paid receipts or invoices verifying the condition/repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by September 30, 1994.
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 the coverage.
We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule/Records and Warranty Booklet.
We regret any inconvenience that you may experience; however, we have taken this action in the interest of your continued satisfaction with our products.
Customer Support Department General Motors of Canada Limited
Dear General Motors Customer:
As the owner of a Buick equipped with a 3.1L engine, your continued satisfaction with our products is of the utmost concern to us. Your vehicle was provided with a new vehicle warranty which covers certain parts of your vehicle 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 1989-91 Buick Regal vehicles built with 3.1L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking (piston slap) noise at low ambient temperatures. This condition will 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 of the date your vehicle was originally placed in service, or 120,000 kilometers, whichever occurs first, your vehicle will be repaired free of charge.
If your vehicle has already experienced cold engine knocking noise, and you have paid to have it repaired, you should contact your GM dealer to seek reimbursement. Please provide your original paid receipts or invoices verifying the condition/repair, the amount charged, proof of your payment and date of payment of those charges. This information must be provided by September 30, 1994.
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 the coverage.
We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule/Records and Warranty Booklet.
We regret any inconvenience that you may experience; 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.
