Exchange Program for Early 2002 Model year 4.2L Engine

This bulletin will cover the 4.2 L Engine Exchange Program only for the 2002 models listed above. This exchange program will be in effect until August 30, 2001. Additional bulletins will be published for each engine or component as they are introduced.

During the 2001 model year the following engines and components will be under an exchange program:

Engines

Components

Product teams continually seek valuable information for product engineering improvements. An exchange program will be administered by GM Powertrain during the 2002 model year. The duration of the program is six months for the above applications. Guidelines for honoring exchange requests under the exchange program are being strictly enforced for the 2002 model year.

You must call the Technical Assistance Center (TAC) to request an exchange. TAC may request the dealer to perform additional work.

If any internal components of a 2002 model year engine require replacement, the engine must be exchanged. Parts of the 4.2 L engine which may be removed and serviced without exchange are identified by an "X" in the right column of the table below.

Engine components on the Serviceable Components list above must be serviced according to the repair procedures in the applicable service information publication (manual). Engine components NOT included in the above list will require an engine exchange.

Important: Engine repairs or failures that are caused by components external to the engine will NOT fall under the exchange program. For example, engine coolant lines incorrectly installed causing an engine failure will have to go through GMSPO to obtain an engine assembly. The exchange program is created as a way to correct internal concerns and to take what is learned and find a way to eliminate these concerns. External components causing a failure do not provide any useful information in improving an engine. The engine received from GMSPO will be a new service engine.

A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements. Contact Technical Assistance, phone numbers listed above, to verify the proper diagnosis has been performed. Upon review of the diagnosis, Technical Assistance will establish a case reference number and make arrangements for shipping an exchange unit to your dealership. To increase the effectiveness of the program, the Warranty Parts Center (WPC) will request the return of the unit removed only upon submission of a warranty reimbursement claim. Therefore, the dealer is strongly encouraged to submit these claims as quickly as possible in order to facilitate the WPC request. DO NOT SHIP AN ENGINE TO THE WPC WITHOUT AN OFFICIAL WPC REQUEST.

Important: Failure to return the concerned engine will result in the dealership being debited in the amount of an entire engine assembly (dealer net).

The removed unit must be returned complete in the original exchange shipping container. For effective engineering analysis, please do not remove any components. Dress items on the removed unit must remain the same as the replacement engine (e.g., exhaust manifolds, throttle body, etc.). Dealerships returning engines/components having been even partially disassembled will be judged as violating this procedure and, as such, will be billed for all materials furnished.

Notice: The exchange unit will be shipped with a quantity of oil; check oil level before starting the engine. Low oil level could result in internal engine damage.

Included with the exchange unit will be return shipping instructions, including a return shipping label (freight collect at destination) and partially completed Bill of Lading.

A request for return of engine or component will be received at the dealership when the appropriate warranty reimbursement claim is paid. (Credit memos and WPC requests are received every Tuesday and Friday.)

Shipping Preparation

1. Remove the engine assembly/component as outlined in the applicable Service Manual. Drain all fluids from the removed engine.
2. Retorque any fasteners that were loosened or removed to the original torque specification.
3. Remove any plastic shipping plugs and covers from the exchange unit and install them on the removed unit.
4. If the concerned engine leaks, mark the area directly on the engine with a permanent marker.
5. Write the TAS case reference number on the repair order form.
6. Write the TAS case reference number on the component in a visible location.
7. Place the removed engine into the original shipping container. Attach completed return shipping tag to engine.

Shipping Instructions

1. Place a copy of the repair order, the completed return checklist and product feedback forms into the plastic press on envelope.
2. Remove the original shipping label and attach the plastic press on envelope with the return shipping label on it to the container. The Bill of Lading and Custom Papers (for Cross-Border Shipments) provided with the exchange engine are the only other documents required to be inserted into the clear envelope to return the removed engine.
3. Write the WPC request number and the TAS case reference number on the outside of the container with a permanent marker. To simplify the Exchange Program's core return process, the WPC will be coordinating all activities for core returns. See Service Bulletin 99-00-89-019 (Dealers in Canada should refer to Home Office Letter 99-201) for detailed shipping information.
4. Ship all returned exchanges/components with appropriate paperwork to:

Third Party Freight Collect

GM Warranty Parts Center

45 Northpointe Drive

Orion, MI 48359

For vehicles repaired under warranty, use:

Important: Applicable miscellaneous items such as engine oil and coolant should be added to the part allowance amount and claimed in the Parts Cost column and not included in the Net Amount (DMN) column of the warranty claim.

Your cooperation is greatly appreciated. Prompt return of the original engine will increase the effectiveness of this program. If you have any questions regarding the exchange program administrative procedures, please contact Technical Assistance.