FORMAL ENGINE EXCHANGE PROGRAM FOR MODEL YEAR. GMC Truck Sonoma Pickup

REVISION: 05/15/96

THIS BULLETIN CANCELS THE FORMAL ENGINE EXCHANGE PROGRAM EFFECTIVE MAY 15, 1996 FOR ALL 1996 MODEL YEAR 4.3L ENGINES. ALL 4.3L ENGINE CONCERNS SHOULD BE SERVICED ACCORDING TO PROCEDURES OUTLINED IN YOUR 1996 SERVICE MANUALS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 57-61-31. ----------------------------------------------------------------------

REVISION: 08/26/96

THIS BULLETIN IS BEING REVISED TO DISCONTINUE THE FORMAL ENGINE EXCHANGE PROGRAM FOR ALL 1996 MODEL YEAR ENGINES AND INITIATES THE 1997 MODEL YEAR ENGINE EXCHANGE PROGRAM. PLEASE DISCARD CORPORATE BULLETIN NUMBER 57-61-31A (SECTION 6 - ENGINE). ----------------------------------------------------------------------

REVISION: 10/24/96

THIS BULLETIN IS BEING REVISED TO (1) ADD GRAND PRIX TO THE 3800 EXCHANGE PROGRAM AND (2) UPDATE PART ALLOWANCE AMOUNTS BASED ON CURRENT DATA. PLEASE DISCARD CORPORATE BULLETIN NUMBER 57-61-31B (SECTION 6 - ENGINE). ----------------------------------------------------------------------

REVISION: 08/14/97

THIS BULLETIN DISCONTINUES THE FORMAL ENGINE EXCHANGE PROGRAM FOR ALL 1997 MODEL YEAR ENGINES AND INITIATES THE 1998 MODEL YEAR ENGINE EXCHANGE PROGRAM. CORPORATE BULLETIN NUMBER 57-61-31C IS SUPERSEDED AND SHOULD BE DISCARDED. ---------------------------------------------------------------------- REVISION: 11/04/97

THIS BULLETIN IS BEING REVISED TO REMOVE THE 1998 OLDSMOBILE INTRIGUE (3.5L ENGINE) AND ADD 1998 CHEVROLET AND GMC S TRUCKS (2.2L ENGINE) TO THE FORMAL ENGINE EXCHANGE PROGRAM. PLEASE DISCARD CORPORATE BULLETIN NUMBER 57-61-31D (SECTION 6 - ENGINE). ----------------------------------------------------------------------

SUBJECT: EXCHANGE PROGRAM - FORMAL ENGINE EXCHANGE PROGRAM FOR 1998 MODEL YEAR

MODELS: 1998 CHEVROLET CAVALIER 1998 PONTIAC SUNFIRE 1998 CHEVROLET AND GMC S TRUCKS WITH 2.2L ENGINE (VIN 4 - RPO LN2)

1998 CHEVROLET CAMARO, CORVETTE 1998 PONTIAC FIREBIRD WITH 5.7L ENGINE (VIN G - RPO LS1)

1998 CHEVROLET P TRUCKS WITH 7.4L ENGINE (VIN B - RPO L21)

BECAUSE PRODUCT TEAMS CONTINUALLY SEEK VALUABLE INFORMATION FOR PRODUCT ENGINEERING IMPROVEMENTS, A FORMAL ENGINE EXCHANGE PROGRAM WILL, ONCE AGAIN, BE ADMINISTERED BY GM POWERTRAIN DURING THE 1998 MODEL YEAR. THE DURATION OF THE FORMAL PROGRAM, HOWEVER, IS SHORTENED TO SIX MONTHS. ROUTINELY, ENGINEERING LEARNINGS FROM AN EXCHANGE PROGRAM ARE FAIRLY COMPLETE AFTER THE FIRST SIX MONTHS OF FIELD EXPERIENCE; CONDITIONS ENCOUNTERED AFTER THAT ARE GENERALLY REPEATS OF PREVIOUSLY FOUND CONCERNS. ALSO, ESTABLISHED CRITERIA FOR INCLUSION IN THE FORMAL ENGINE EXCHANGE PROGRAM ARE BEING STRICTLY ENFORCED FOR THE 1998 MODEL YEAR.

IN THE INTEREST OF CONSISTENCY AND BETTER COMMUNICATION, THIS SINGLE BULLETIN SERVES TO CANCEL THE PREVIOUS (1997) MODEL YEAR FORMAL ENGINE EXCHANGE PROGRAM AND ANNOUNCE THE 1998 MODEL YEAR ENGINE EXCHANGE PROGRAM. THE ENGINES FOR APPLICATIONS (MODELS) IDENTIFIED ABOVE WILL BE EXCHANGED DURING THE 1998 MODEL YEAR PROGRAM WHICH IS OUTLINED BELOW.

2.2L (VIN 4 - RPO LN2) SEPTEMBER 1, 1997 THROUGH FEBRUARY 28, 1998 5.7L (VIN G - RPO LS1) SEPTEMBER 1, 1997 THROUGH FEBRUARY 28, 1998 7.4L (VIN B - RPO L21) JANUARY 1, 1998 THROUGH JUNE 30, 1998

AS IN PAST ENGINE EXCHANGE PROGRAMS, YOU MUST CALL YOUR DIVISIONAL TECHNICAL ASSISTANCE GROUP. YOU MAY BE REQUESTED TO PERFORM SOME BASIC DIAGNOSTICS WHICH CAN INCLUDE PARTIAL DISASSEMBLY OF SOME COMPONENTS. ONCE TECHNICAL ASSISTANCE HAS THE DATA REQUIRED, AN ENGINE EXCHANGE MAY BE AUTHORIZED.

IF ANY INTERNAL COMPONENTS OF A 1998 MODEL YEAR ENGINE REQUIRE REPLACEMENT, THE ENGINE MUST BE EXCHANGED. COMPONENTS OF 1998 ENGINES WHICH **MAY** BE SERVICED WITHOUT EXCHANGE OR REMOVED FOR DIAGNOSIS ARE IDENTIFIED BY AN "X" BELOW IN EACH ENGINE TYPE COLUMN.

|PASSENGER| | CAR | TRUCK | ENGINES |ENGINE | - - - - | - - - SERVICEABLE COMPONENTS |2.2L|5.7L| 7.4L - - - - - - - - - - - - - - - | - -|- - | - - - ACCESSORY DRIVE/DRIVE SYSTEM | X | X | X ALL ENGINE SENSORS | X | X | X IAT SENSOR | X | X | X MAP SENSOR | X | X | X TP SENSOR | X | X | X BLOCK HEATER (IF APPLICABLE) | X | X | X BRACKETS | X | X | X ENGINE/TRANSAXLE MOUNTS | X | N/A| N/A CAM COVERS/GASKETS | X | X | X COOLANT OUTLET (NOT CROSSOVER)| X | X | X COOLANT PUMP/DRIVE SYSTEM | X | X | X EGR SYSTEM/COMPONENTS | X | X | X ELECTRONIC COMPONENTS | X | | X EXHAUST MANIFOLD/GASKETS | X | X | X FLYWHEEL ASSEMBLY | X | X | X FRONT COVER/GASKET | X | | X FRONT COVER OIL SEAL | X | | X FUEL SYSTEM | X | X | X HARMONIC BALANCER | X | | X HEATER PIPES/O-RINGS | X | X | X IGNITION (COIL MODULE, SPARK | X | X | X PLUGS, HIGH VOLTAGE SWITCH, | | | WIRES) | | | INJECTOR WIRING HARNESS | X | N/A| X INTAKE MANIFOLD (LOWER FOR TWO| X | X | X PIECE) | | | UPPER INTAKE (FOR TWO PIECE | N/A| X | X **ONLY**) | | | OIL FILTER ADAPTER/SEALS | X | X | X OIL LEVEL INDICATOR/TUBE | X | X | X OIL PAN AND GASKET | X | | X OIL PUMP ASSEMBLY | X | | X PCV SYSTEM | N/A| X | X STARTER MOTOR | X | X | X THERMOSTAT HOUSING/GASKET | X | X | X THROTTLE BODY/RELATED | X | | X COMPONENTS | | | VACUUM TUBES | X | X | X VALVE COVERS/GASKETS | X | X | X WATER PUMP | X | X | X

DEFICIENT ENGINE COMPONENTS ON THE "SERVICEABLE COMPONENT" LIST ABOVE MUST BE SERVICED ACCORDING TO THE REPAIR PROCEDURES IN THE APPLICABLE SERVICE INFORMATION PUBLICATION (MANUAL). DEFICIENT ENGINE COMPONENTS **NOT** INCLUDED IN THE ABOVE LIST WILL REQUIRE AN ENGINE EXCHANGE.

PROCEDURES CONTACT TECHNICAL ASSISTANCE TO ESTABLISH A CASE REFERENCE NUMBER AND TO MAKE ARRANGEMENTS FOR SHIPPING AN EXCHANGE UNIT TO YOUR DEALERSHIP. TO INCREASE THE EFFECTIVENESS OF THE PROGRAM, THE UNIT REMOVED FROM THE VEHICLE MUST BE RETURNED IMMEDIATELY (NOT LATER THAN 7 DAYS AFTER THE RECEIPT OF THE REPLACEMENT UNIT).

**FAILURE TO RETURN THE CONCERNED ENGINE WILL RESULT IN THE DEALERSHIP BEING BILLED THE DEALER NET COST OF THE EXCHANGED ENGINE.**

THE REMOVED UNIT MUST BE RETURNED COMPLETE IN THE EXCHANGE ENGINE SHIPPING CONTAINER. FOR EFFECTIVE ENGINEERING ANALYSIS, PLEASE DO NOT REMOVE ANY COMPONENTS. ENGINE DRESS ON THE REMOVED UNIT MUST REMAIN THE SAME AS THE REPLACEMENT ENGINE (E.G., EXHAUST MANIFOLDS, THROTTLE BODY, ETC.). ANY REINSTALLED COMPONENTS MUST BE ADEQUATELY TORQUED (I.E., TO SPEC) TO AVOID OPERATOR INJURY DURING PRE-TEARDOWN TESTING AT THE PLANT. DEALERSHIPS RETURNING ENGINES HAVING BEEN EVEN PARTIALLY DISASSEMBLED WILL BE JUDGED AS VIOLATING THIS PROCEDURE AND, AS SUCH, WILL BE BILLED FOR ALL MATERIALS FURNISHED.

THE EXCHANGE UNIT WILL BE SHIPPED WITH A QUANTITY OF OIL; CHECK OIL LEVEL BEFORE STARTING ENGINE.

INCLUDED WITH THE EXCHANGE UNIT WILL BE RETURN SHIPPING INSTRUCTIONS, INCLUDING A RETURN SHIPPING LABEL (FREIGHT COLLECT AT DESTINATION) AND A PARTIALLY COMPLETED BILL OF LADING.

SHIPPING PREPARATION **DRAIN ALL FLUIDS FROM THE REMOVED ENGINE AND INSTALL ANY PLUGS TAKEN OFF THE EXCHANGE ENGINE.**

REMOVE THE ENGINE ASSEMBLY AS OUTLINED IN THE APPLICABLE SERVICE MANUAL. REMOVE ANY PLASTIC SHIPPING PLUGS AND COVERS FROM THE EXCHANGE UNIT AND INSTALL THEM ON THE REMOVED UNIT.

IF THE CONCERNED ENGINE LEAKS, MARK THE AREA DIRECTLY ON THE ENGINE. WRITE THE TECHNICAL ASSISTANCE CASE REFERENCE NUMBER ON THE REPAIR ORDER FORM.

RECRATE THE REMOVED ENGINE INTO THE ORIGINAL SHIPPING CONTAINER. PLACE A COPY OF THE REPAIR ORDER AND THE COMPLETED IDENTIFICATION CARD IN AN ENVELOPE AND ATTACH THE ENVELOPE TO THE ENGINE BEING RETURNED.

SHIPPING INSTRUCTIONS REMOVE THE ORIGINAL SHIPPING TAG AND ATTACH THE RETURN SHIPPING LABEL TO THE CONTAINER. THE BILL OF LADING AND CUSTOM PAPERS (CANADA ONLY) PROVIDED WITH THE EXCHANGE ENGINE ARE THE ONLY DOCUMENTS REQUIRED TO RETURN THE REMOVED ENGINE.

**IMPORTANT:** CF LOGISTICS IS COORDINATING ALL EXCHANGE ENGINE RETURNS. THEIR HOURS OF OPERATION ARE 7:00 A.M. TO 6:00 P.M. CENTRAL TIME, MONDAY THROUGH FRIDAY. YOU MAY CONTACT THEM AT 1-800-260-7834 TO ARRANGE FOR EXCHANGE ENGINE CORE PICKUP. USE GROUND FREIGHT ONLY!

AFTER THE BILL OF LADING HAS BEEN DATED AND SIGNED BY THE CARRIER, RETAIN THE LAST COPY WITH YOUR REPAIR ORDER AND PROVIDE THE OTHER COPIES TO THE CARRIER. **YOUR COPY OF THE BILL OF LADING, SIGNED BY THE CARRIER, IS YOUR PROOF OF RETURNING THE ENGINE.**

THE REMOVED ENGINE IS TO BE SHIPPED BY CF MOTORFREIGHT--COLLECT--TO THE ENGINE PLANT OF ORIGIN (AGAIN, CONTACT CF IF YOU HAVE QUESTIONS REGARDING PROPER CORE RETURN PROCEDURES). PLEASE **IDENTIFY** THE DEALER ADDRESS (I.E., THE RETURN ADDRESS) AND **TECHNICAL ASSISTANCE CASE REFERENCE NUMBER** ON THE OUTSIDE OF THE CRATE.

IF THE ENVELOPE CONTAINING SHIPPING INFORMATION BECOMES LOST, PLEASE CONTACT CF LOGISTICS AT 1-800-260-7834 FOR SHIPPING INSTRUCTIONS OR THE APPROPRIATE ENGINE PLANT AT NUMBERS LISTED BELOW.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - | ADDRESS TO: GM POWERTRAIN ENGINE PLANT | FOR SHIPPING DISP | ATTN: (DISP) ENGINE EXCHANGE | INFO, CALL - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - | TONAWANDA - RIVER ROAD | 2.2L | TONAWANDA, NY 14150 | 716-879-5123 | ATTN: TERRY BEIMLER | - - - - - -|- - - - - - - - - - - - - - - - - - - - - -|- - - - - - - | ROMULUS - 36880 ECORSE ROAD | 5.7L | ROMULUS, MI 48174-0910 | 313-595-5013 | ATTN: KEN BECKER | - - - - - -|- - - - - - - - - - - - - - - - - - - - - -|- - - - - - - | TONAWANDA - RIVER ROAD | 7.4L | TONAWANDA, NY 14150 | 716-879-5352 | ATTN: TERRY BEIMLER | - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

WARRANTY CLAIMS PROCESSING PROCEDURE USE THE FOLLOWING INFORMATION FOR CLAIM SUBMISSION:

LABOR LABOR* PART HANDLING OPERATION HOURS DESCRIPTION ALLOWANCE --------- ----------- ----------- ------------- J1880 0.2 HR REPLACE ENGINE ASSEMBLY 2.2L ENGINE $ 380.00 5.7L ENGINE (F CAR) 670.00 5.7L ENGINE (Y CAR) 675.00 7.4L ENGINE 735.00

* USE PUBLISHED LABOR TIME PLUS THE ADMINISTRATIVE ALLOWANCE INDICATED ABOVE; REPORT AS REGULAR LABOR TIME.

**IMPORTANT:** APPLICABLE MISCELLANEOUS ITEMS SUCH AS ENGINE OIL AND COOLANT SHOULD BE ADDED TO THE PART ALLOWANCE AMOUNT AND INCLUDED IN THE NET AMOUNT (DMN) COLUMN OF THE WARRANTY CLAIM.

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS REGARDING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT DIVISIONAL TECHNICAL ASSISTANCE (MISCELLANEOUS GROUP / ENGINE MECHANICAL).

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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.