Customer Satisfaction 99063A - Mismachined Engine Crankshaft

This bulletin is being revised to include service procedures, labor time, additional parts information and disposition instructions required to replace the engine. Please discard Customer Satisfaction Bulletin Number 99063, dated October, 1999.

THIS REVISION OF THE CAMPAIGN BULLETIN ADDRESSES VEHICLES IN DEALER INVENTORY AND ALSO VEHICLES DELIVERED TO CUSTOMERS. VEHICLES THAT PASS THE INSPECTION PROCEDURE WILL BE RELEASED FROM THE STOP DELIVERY ISSUED SEPTEMBER 30, 1999 VIA DCS MESSAGES WIS19990028 THROUGH WIS19990043. ALL VEHICLE VINS AFFECTED BY THIS CAMPAIGN HAVE BEEN LOADED IN VISS. ANY VINS HELD BY THE ABOVE "STOP DELIVERY," BUT NOT IN VISS ARE NOT AFFECTED BY THIS CAMPAIGN AND CAN BE RELEASED. DEALER INVENTORY VEHICLES THAT DO NOT PASS THE INSPECTION ARE NOT TO BE DELIVERED TO CUSTOMERS. THERE ARE SPECIAL INSTRUCTIONS FOR CUSTOMER VEHICLES THAT DO NOT PASS THE INSPECTION. REFER TO THE SERVICE PROCEDURE FOR DETAILS.

CUSTOMERS INVOLVED IN THIS CAMPAIGN WILL BE NOTIFIED BY GM BEGINNING NOVEMBER 29, 1999.

General Motors has decided that certain 2000 model year Chevrolet, GMC and Oldsmobile S/T, M/L and C/K (Silverado/Sierra) model trucks, equipped with 4.3L V6 engine (RPO L35-VIN Code W), may exhibit a condition in which the engine oil pressure may decrease. This may cause premature engine bearing failure. The cause of this condition is a mismachined engine crankshaft lightening hole that will divert engine oil away from the #1 connecting rod journal oil feed passage.

To prevent the possibility of this condition occurring, dealers are to inspect the engine crankshaft for breakthroughs between the lightening hole and the #1 connecting rod journal oil feed passage. If this condition exists in a vehicle in dealer inventory, the dealer should replace the engine and then return the vehicle to General Motors Corporation (do not deliver the vehicle to a customer). For vehicles that have been delivered to customers and are leased by the customer and have this condition, the engine will be replaced and the customer will be provided with new GM SmartCare coverage. For vehicles that have been delivered to and are owned by customers and have this condition, the customer will be given the option of (1) having a replacement engine installed and receiving a new 5 year/60,000 mile GM Protection Plan Policy or (2) trading the vehicle in for a new, comparable vehicle in dealer inventory. If the customer elects to exchange the vehicle, the dealer is to replace the engine after the exchange and then return the vehicle to General Motors.

Involved are certain 2000 model year Chevrolet, GMC and Oldsmobile S/T, M/L and C/K (Silverado/Sierra) model vehicles equipped with 4.3L V6 engine (RPO L35-VIN Code W) and built within the following VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through VISS (Vehicle Information Service System) prior to beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number have been prepared, and are being furnished to involved dealers with the campaign bulletin. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

Important: RPO K18 indicates the vehicle is equipped with AIR injection and is noted on the service parts identification label of the vehicle.

Important: It is estimated that only 20% of involved vehicles will require engine replacement. Parts should only be ordered when inspection determines that it is necessary to replace the engine.

Customers will be notified of this campaign on their vehicles by General Motors (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Combined Truck Model Crankshaft Inspection

1. Disconnect the negative battery cable.
2. Raise and suitably support the vehicle.
3. Remove the oil pan drain plug and drain the engine oil into an appropriate container for disposal.
4. For all vehicles except T trucks, remove the oil filter.
5. For K and T trucks only, remove the splash shield and the oil pan/front skid plate.
6. For all vehicles except C/K trucks, remove the oil filter adapter and the oil filter adapter gasket.
7. For C/K trucks only, remove the bolts holding the battery cable brackets to the oil pan.
8. For all vehicles except C/K trucks, remove the oil cooler line bracket bolt from the oil pan.
9. For T trucks only, remove the differential carrier shield mounting bolts, if equipped.
10. For T trucks only, remove the differential carrier shield, if equipped.
11. Remove the bolt holding the bracket for the starter wire harness and, if equipped, the transmission oil cooler pipes.
12. Remove the starter motor mounting bolts and any shims previously used.
13. Lower and support the starter motor.
14. Remove the transmission cover bolts and the cover.
15. For M/L vans only, remove the crankshaft position sensor wire from the clip.
16. For S trucks only, remove the antilock brake system (ABS) wiring harness from the clips.
17. Remove the transmission to oil pan bolts.
18. Remove the access plugs for the oil pan rear nuts.
19. Remove the oil pan bolts and the oil pan rear nuts.
20. For L vans only, remove the inner axle shaft housing support bracket to the frame nuts and the washers.
21. For M vans only, remove the bolts that retain the forward edge of the right crossmember brace to the frame.
22. For M vans only, remove the bolt and the nut that retain the rear edge of the right crossmember brace to the frame.
23. For M vans only, remove the right crossmember brace from the frame.
24. For T trucks only, remove the right axle shaft housing support bracket to frame bolts.
25. For T trucks only, turn the steering wheel to gain clearance from the linkage and the pull downward on the right axle shaft for better clearance.

Notice: Care must be taken while lowering the oil pan to prevent damage to the oil pan gasket by inserting a putty knife between the engine block and the pan at the corners of the pan to gently separate the oil pan gasket from the adhesive bead on the engine block. If the oil pan gasket is damaged, it must be replaced, provided the engine passes inspection.

26. Lower the oil pan until it rests on the crossmember or the front differential.
27. Remove the flywheel housing access plug from the transmission.
28. Rotate the flywheel until the #1 connecting rod throw is in the 6 o'clock position.

Front View of Engine Crankshaft

Truck/Engine Replacement Customer Discussion Guide

THIS DOCUMENT IS INTENDED AS A DISCUSSION GUIDE BETWEEN THE DEALER AND THE OWNER ONCE A VEHICLE HAS BEEN INSPECTED AND DETERMINED TO EXHIBIT THE CONDITION.

We have inspected your vehicle's engine and found a breakthrough in the crankshaft.

Your complete satisfaction with your 2000 Chevrolet, GMC or Oldsmobile <S/T, M/L or C/K (Silverado/Sierra)> truck is important to us and we encourage you to choose the option that is satisfactory to you.

GMPP/SmartCare Processing -- Engine Replacement Only

1. Fill out the application for GMPP or SmartCare, to be owned by the customer. These plans are only available within 12 months of the date of vehicle purchase or lease. Submit the application to Plan Headquarters, noting that you have a customer whose vehicle has had the engine replaced on campaign 99063A and that you need to provide GMPP or SmartCare coverage. When completing the application use the special code number 299124 in the dealer code field instead of the dealer code. If the customer's vehicle usage is defined as "commercial multi-driver" by GMPP, you must select the appropriate coverage. The GMPP will be 60 months/60,000 mile Major Guard with no deductible. SmartCare will be for the term of the vehicle lease.
2. There will be no charge to dealers or customers for these plans.
3. The customer will receive a GMPP or SmartCare verification in the mail.

Important: In the event a customer purchased GMPP at the time of new vehicle sale, or SmartCare at the time of new vehicle lease, CAC will assist in processing a refund of the customer's purchase price for the respective plan while the customer retains plan coverage on the vehicle. If the customer's original purchase included purchase of a non-GMPP plan, please review this issue with CAC.

Customer Vehicle Repurchases (Not Available for Leased Vehicles)

If a customer chooses to have a vehicle repurchased and replaced by a vehicle in dealer stock:

1. Contact the Business Resource Center (BRC) at 1-800-231-1841 and follow the prompts to reach the appropriate divisional BRC repurchase Customer Relations Managers. This phone is intended for dealer use only. Advise BRC that you have a customer with a repurchase request for campaign 99063A. The BRC will provide a file number if it has not been previously established.
2. Replacement vehicles are restricted to comparable units currently in dealer inventory and transactions should occur without usage, licensing or sales tax charges to the customer. Minor vehicle specification differences, representing $500 or less difference in MSRP, should be reviewed with BRC to determine the appropriate adjustment. Replacement vehicles will be repurchased from the dealer at the 310 account level.
3. BRC will complete vehicle repurchase arrangements with the dealer and the customer.
4. The dealer must replace the engine in repurchased vehicles following the same procedure as used for dealer stock vehicles.
5. Once engine replacement is complete and repurchase paperwork has been received by the dealer, the dealer should advise the Regional Vehicle Disposition Center (RVDC) at 1-888-567-3234. The RVDC will make arrangements to have the vehicle picked up from the dealer and processed to auction as a GM repurchased vehicle.

Vehicles in Dealer Inventory

Vehicles in dealer inventory, which have had the engine replaced and warranty claim submitted, are to remain on "Stop Delivery." Additional instructions will be provided relative to dealer invoice credit, floor plan and vehicle return disposition to General Motors.

Ordering "Factory-Shipped" Engines Through GMSPO

Locate the 3-letter Broadcast Code (B/C) on the right side of the oil pan, left rear cylinder head and/or the right front rocker cover. Match this B/C with the part number from the "Parts Information" table in this bulletin. Use this engine part number to order the "Factory-Shipped" engine from GMSPO.

Engine Removal

Refer to the Engine section of the appropriate Service Manual for the engine removal procedure.

Engine Component Transfer

Refer to the Engine section of the appropriate Service Manual for engine component removal and installation procedures.

These are "Factory-Shipped" engines with higher component content and do not require as many component transfers as a "Goodwrench" engine. These differences are already reflected in the listed campaign labor times.

Engine Installation

Refer to the Engine section of the appropriate Service Manual for the engine installation procedure.

Important: Because the accelerator control cable is new (less than 10,000 miles), the accelerator control cable does not require replacement. After engine replacement, verify that the throttle system operates freely and that the throttle system returns immediately to idle.

Install the GM Campaign Identification Label.

Engine Dispositions for Replaced Engines

These engines will be requested for return by the Warranty Parts Center (WPC). WPC request will be sent via DCS on the same day claim payment is received by the dealership. Do not return the engine without the WPC request without the WPC request and repair order.

Dealers are encouraged to process their warranty claims as quickly as possible in order to expedite the engine return requests from WPC. Dealers will receive a WPC request via DCS on the same day the claim is paid.

The following procedures must be followed with regard to return of the engine:

1. Ship immediately upon receipt of the WPC return request.
2. The crate, which contained the replacement engine, should be used.
3. TWO COPIES of the WPC request and repair order MUST accompany the engine. Attach one copy of paperwork to the engine and the second copy to the bill of lading.
4. WRITE THE WPC REQUEST NUMBER ON THE TOP OF THE CRATE.
5. Informational Service Bulletin 99-00-89-019 (issued 10/99) contains all necessary shipping instructions.

Do not include other unrelated parts with this shipment to the WPC. However, the content of these returned engines should equal the content of the replacement engine.

Each vehicle inspected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label" IF NO BREAKTHROUGHS ARE FOUND, OR AFTER THE ENGINE HAS BEEN REPLACED. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in by the customer for periodic servicing. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels can be obtained from Dealer Support Materials by calling 1-888-414-6322 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Apply the "Campaign Identification Label" only on a clean, dry surface.

Submit a Product Campaign Claim with the information indicated below.

Refer to the General Motors Corporation Claims Processing Manual for details on Product Campaign Claim Submission.

Dear (Chevrolet, GMC, Oldsmobile) Customer:

This notice is sent to inform you that General Motors is conducting a customer satisfaction campaign that includes your vehicle.

The 4.3L V6 engine in your 2000 model year Chevrolet, GMC or Oldsmobile <S/T, M/L, C/K (Silverado/Sierra)> truck may contain a crankshaft that has a hole because it was not made properly. This can reduce engine oil pressure and cause premature engine bearing failure.

To prevent the possibility of this condition occurring, your dealer will inspect the engine crankshaft for an improper hole.

The inspection may show no problem (this will be the situation for most customers). General Motors will offer those customers a free follow-up oil and filter change at the next regularly scheduled oil change interval.

If the inspection shows the engine in your truck has this problem, General Motors will do the following:

Your complete satisfaction with your 2000 Chevrolet, GMC or Oldsmobile <S/T, M/L or C/K (Silverado/Sierra)> truck is important to us and we encourage you to choose the option that is most convenient for you.

Please contact your <<Division>> dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process, and repair your vehicle.

If you experience any trouble scheduling your vehicle or you have any questions regarding this recall action, please contact the appropriate Customer Assistance/Relations Center at the number listed below:

The enclosed customer reply card identifies your vehicle. Presentation of this card 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 postage paid reply card and returning it to us.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor, Pontiac-GMC, Oldsmobile Division

General Motors Corporation

Enclosure