Customer Satisfaction - 4.2L Inline 6 Cyl Engine - Cylinder Block Machined Incorrectly - Replace Engine

THIS PROGRAM IS IN EFFECT UNTIL MARCH 31, 2009.

Certain 2009 model year Chevrolet Trailblazer and GMC Envoy model vehicles, equipped with 4.2L inline 6 Cylinder (RPO LL8 - VIN S) engine, may have a condition in which the cylinder block bore chamfer on number one cylinder was machined too deeply such that the bore liner’s top lip may be unsupported, leading to cracking of the bore liner. A cracked bore liner may lead to subsequent piston and engine damage. The customer would experience engine noise followed by engine failure.

Important: This program will expire on March 31, 2009.

Dealers are to replace the engine.

Involved are certain 2009 model year Chevrolet Trailblazer and GMC Envoy model vehicles equipped with a 4.2L inline 6 Cylinder (RPO LL8 - VIN S) engine and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GM Vehicle Inquiry System (GMVIS). Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

- US GM dealers - GM DealerWorld Recall Information

The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.

The replacement engine should only be ordered from the Product Quality Center (PQC). Contact the Product Quality Center (PQC) and request an engine assembly. The full 17-character VIN will be required. All removed engines should be held until a Warranty Parts Center (WPC) request for return is received. DO NOT SHIP AN ENGINE TO THE WPC WITHOUT AN OFFICIAL WPC REQUEST. If you do not receive a WPC Request, contact Annette Quince at 248-371-9939.

1. Refer to SI for engine exchange procedure.
2. Contact the Product Quality Center (PQC) and request an engine. The full 17-character VIN, and the 08328 bulletin reference number will be required when ordering.

Caution: To avoid spillage when removing from the shipping container, do not tilt the engine excessively. Do not destroy the container as it will be reused to ship the removed engine to the WPC. Check fluid levels after installation.

3. Refer to SI and replace the engine. The removed engine should be held until a Warranty Parts Center (WPC) request for return is received. DO NOT SHIP WITHOUT AN OFFICIAL WPC REQUEST. If you do not receive a WPC Request, contact Annette Quince at 248-371-9939.
4. After the engine is installed in the vehicle. The following service procedure should be used to test the engine:

4.1.	Disable the ignition system.

4.2.	Crank the engine several times. Listen for unusual noises or evidence that parts are binding.

4.3.	Enable the ignition system.

4.4.	Start the engine and listen for unusual noises.

4.5.	Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.

4.6.	Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.

4.7.	Listen for a sticking lifter and other unusual noises.

4.8.	Inspect for fuel, oil and/or coolant leaks while the engine is running.

4.9.	Perform a final inspection for the proper engine oil and coolant levels.

5. Return the removed engine to the WPC following the procedures outlined in bulletin 99-00-89-019E, including the draining of fluids.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles.

Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through March 31, 2009.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service through March 31, 2009, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

We have learned that your 2009 model year Chevrolet Trailblazer and GMC Envoy model vehicles, equipped with 4.2L inline 6 Cylinder (RPO LL8 - VIN S) engine, may have a condition in which the cylinder block bore chamfer on number one cylinder was machined too deeply such that the bore liner’s top lip may be unsupported, leading to cracking of the bore liner. A cracked bore liner may lead to subsequent piston and engine damage. The customer would experience engine noise followed by engine failure.

Your satisfaction with your 2009 model year Chevrolet Trailblazer or GMC Envoy is very important to us, so we are announcing a program to prevent this condition or, if it has occurred, to fix it.

What We Will Do: To prevent this condition from occurring, your dealer will replace the engine. This service will be performed for you at no charge until March 31, 2009.

What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

Customer Reply Form: The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below.

Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner’s Manual and your dealer for details on Courtesy Transportation.

We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

08328