CAMPAIGN:STARTER MOTOR PINION STOP. GMC Truck Safari

SUBJECT: STARTER MOTOR PINION STOP

Models: 1994 Chevrolet Cavalier, Corsica/Beretta, Lumina, Lumina Minivan, Chevrolet S/T, C/K Truck, M/L, G-Van, Buick Skylark, Century, Regal, LeSabre, Park Avenue and Cadillac DeVille

TO: ALL GENERAL MOTORS DEALERS

General Motors of Canada Limited has determined that certain 1994 Chevrolet Cavalier, Corsica/Beretta, Lumina, Lumina Minivan, Chevrolet S/T, C/K Truck, M/L, G-Van, Buick Skylark, Century, Regal, LeSabre, Park Avenue and Cadillac DeVille model vehicles listed in this campaign may have a starter motor with an improperly heat treated pinion stop collar. This condition may result in part failure causing slow engine crank speeds or an engine no start condition.

To prevent the failure from occurring, dealers are to inspect and repair certain starter motors from the vehicles identified below. Starter motors with date codes of N093, N103, N113, N123, N153 and N163 are to be repaired by replacing the pinion stop collar and retaining ring. No repairs are necessary on motors that fall outside of these date codes.

VEHICLES INVOLVED:

Involved are certain 1994 vehicles built within the following VIN breakpoints:

CHEVROLET:

--------- ENGINE PLANT YEAR MODEL PLANT CODE CODE FROM THROUGH ---- ----- ----- ------ ----- ---- ------- 1994 Cavalier Lordstown 4 "7" R7182409 R7196426 1994 Cavalier Lordstown T "7" R7182411 R7196427 1994 Corsica/Beretta Wilmington 4 "Y" RY148458 RY153462 1994 Corsica/Beretta Wilmington A "Y" RY148865 RY153328 1994 Corsica/Beretta Wilmington M "Y" RY142451 RY153463 1994 Lumina Oshawa #1 T, X "9" R9157236 R9169993 1994 Lumina Oshawa #2 T, X "1" R1113283 RT116633 1994 Lumina Minivan Tarrytown D, L "T" RTI13391 RT116863 1994 S Truck Shreveport 4 "8" R8131194 R8139429 1994 S Truck Linden 4 "K" RK121601 RK126938 1994 S/T Truck Shreveport Z, w "8" R8133517 R8139431 1994 S/T Truck Moraine Z, w "2" R2137754 R2149488 1994 S/T Truck Linden Z, w "K" RK112441 RK126948 1994 MiniVan Baltimore Z, w "B" RB144075 RB151843 1994 C/K Truck Pontiac East H, Z "E" RE157010 RE162518 1994 C/K Truck Oshawa #2 H, Z "1" R1164759 R1169974 1994 C/K Truck Fort Wayne H, Z "Z" RZ155486 RZ161544 1994 G-Van Flint H, Z "F" RF128363 RF131337

BUICK:

----- ENGINE PLANT YEAR MODEL PLANT CODE CODE FROM THROUGH ---- ----- ----- ------- ------ ---- ------- 1994 Skylark Lansing 3 "C" RC261851 RC264449 1994 Skylark Lansing M "C" RC260550 RC263400 1994 Century Oklahoma City 4 & M "6" R6424800 R6432163 1994 Regal Oshawa M & L "1" R1435735 R1444166 1994 Lesabre Buick City L "H" RH451921 RH458714 1994 Park Avenue Wentzville L & 1 "1" R1627585 R1632784

CADILLAC:

-------- ENGINE PLANT YEAR MODEL PLANT CODE CODE FROM THROUGH ---- ----- ----- ------ ----- ---- ------- 1994 DeVille Hamtramack B "U" RU223740 RU231486

NOTE: PLEASE CHECK DCS SCREEN 4S OR YOUR V.I.N. LISTING BEFORE PERFORMING CAMPAIGN TO ENSURE THAT THE VEHICLE IS AFFECTED. ONLY AFFECTED VIN'S WILL BE PAED.

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

DEALER CAMPAIGN RESPONSIBILITY:

All unsold new vehicles in dealer's possession and subject to this campaign MUST be held and inspected/repaired per the Service Procedure of this Campaign Bulletin before owners take possession of these vehicles.

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometers traveled, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owner letter accompanying this bulletin. Campaign follow- up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign is taken into your new or used vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail, from General Motors (see copy of owner letter included with this bulletin). The listings provided are for campaign activity only and should not be used for any other purpose.

PARTS INFORMATION

Parts required to complete this campaign should be ordered through regular channels, as follows:

IMPORTANT: GMSPO HAS LIMITED QUANTITIES OF PARTS WHICH ARE IN MERCHANDISED PACKAGES OF 10 PIECES EACH. PLEASE DO NOT OVER ORDER TO ENSURE AVAILABILITY TO ALL VEHICLES INVOLVED.

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 1927849 Pinion Stop Collar 1

1927848 Retaining Ring 1

PARTS AND LABOUR CLAIM INFORMATION:

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ----------- -------------- 1A Inspect - No Repair Required - .3 Starter Removal Not required

2A Inspect - No Repair Required - .8

Starter Removal Required 3A Inspect - Starter Repaired 1.3

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 40% to cover parts handling.

SERVICE PROCEDURE

STARTER MOTOR REMOVAL AND REPLACEMENT

INSPECTION:

---------- 1. All vehicles within breakpoints should be inspected to determine starter motor date codes. Date codes are imprinted on upper half of tag located on motor end of starter. Tag information is read upside down as viewed from bottom (see illustration).

2. A.) Most vehicles may be inspected by utilizing a mirror, flashlight, and/or use of a pliable material such as modeling clay or similar material to make an impression of the date code. After making an impression, read code with a mirror.

B.) Some vehicles such as A & W-Cars with L82 engines may require removal of an oil filter drip pan to gain access to read the date codes.

C.) Some vehicles equipped with oil coolers (T Trucks) will require starter motor removal to read date codes per section 6D2 of the service manual.

3. Remove all starter motor assembly per instructions in appropriate 1994 service manual section 6D2 with date codes N093, N103, N113, N123, N133, N153 & N163 and perform pinion stop collar procedure.

Notice: Disconnect negative battery cable after noting radio station settings.

4. Reinstall starter motor per instructions in service manual, section 6D2. Reset radio settings as noted and reset clock.

5 . Install Campaign Identification Label.

PINION STOP COLLAR REPLACEMENT PROCEDURE

1. Remove field lead attaching screw from solenoid terminal.

2. Loosen but do not remove through bolts in starter motor assembly. Do not separate the commutator end and frame.

3. Separate frame with armature inside from housing.

4. Remove thrust collar from end of shaft if it is not stuck to housing.

5. Use care in removing and installing retaining ring to prevent scratching or damaging armature shaft.

6. Remove pinion stop retaining ring first by prying pinion stop collar off the ring. Pry pinion stop ring off armature with a small screw driver. Do not reuse ring.

7. Remove pinion stop collar from armature shaft. Do not reuse collar.

8. Install new pinion stop collar on armature shaft. Flat side goes towards pinion.

9. Install new retaining ring onto armature shaft and seat it in shaft groove. Use due care not to damage armature shaft.

10. Install thrust collar onto armature shaft with small flange toward retaining ring. Use two pliers to squeeze pinion stop collar and the thrust collar to seat the stop collar on the retaining ring.

11. Assemble frame, armature and drive assembly into housing. Ensure shift lever is engaged with drive assembly. Ensure armature shaft is engaged with housing bearing. Tighten through bolts.

12. Install starter field lead to solenoid. Return to step 4 of INSPECTION.

13. Install Campaign Identification Label.

INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer,

To prevent the failure from occurring, your dealer will inspect and, if necessary, repair the starter motor on your vehicle.

This service will be provided for you at no charge.

Please contact your GM dealer as soon as possible to arrange a service date.

If parts are required, ask your dealer for details regarding their availability. If parts are not in stock, they can be ordered before scheduling your service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

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

Customer Support Department General Motors of Canada Limited

Object Number: 77836 Size: FS

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.