CAMPAIGN: QUAD 4 IGNITION COIL INSPECT COIL CASE FOR CRACKS
Subject: QUAD 4 IGNITION COIL
Models/Years: 1987-90 CUTLASS CALAIS AND 1990 CUTLASS SUPREME WITH 2.3L ENGINE (VIN CODE D or A)
CONDITION
General Motors has determined that some 1987-90 Oldsmobile Cutlass Calais models and 1990 Cutlass Supreme models equipped with 2.3L (VIN Code D or A) engines (options LD2 or LGO) may develop cracks in the case of the I.D.I. (Integrated Direct Ignition) coil at the high voltage terminals. As the cracks grow, external arcing occurs between terminals and/or terminal to coil frame resulting in intermittent misfire, rough idle, and ultimately a "no start' condition when the coil falls completely.
Dealers are to inspect the ignition coils, and, if necessary, replace coils as instructed in the SERVICE PROCEDURE section of this bulletin.
VEHICLES INVOLVED
Involved are certain 1987-90 Oldsmobile Cutlass Calais models and 1990 Cutlass Supreme models equipped with 2.3L (VIN Code D or A) engines (options LD2 or LGO) within the breakpoints listed below:
MODEL RPO/VIN 1987 1988 1989 1990 EMISSIONS ----------------------------------------------------------------------------- Cutlass Calais LD2/D All All All S.O.P. Thru LM767173 NA5 Cutlass Calais LGO/A - - All S.O.P. Thru LM766825 NA5 Cutlass Calais LGO/A - - All S.O.P. Thru LM764460 NB2 Cutlass Supreme LD2/D - - - S.O.P. Thru LD400017 NA5 Cutlass Supreme LD2/D - - - S.O.P. Thru LD400784 NB2 Cutlass Supreme LGO/A - - - S.O.P. Thru LD401389 NA5 Cutlass Supreme LGO/A - - - S.O.P. Thru LD401165 NB2
S.O.P. means "Start of Production".
NOTICE: Vehicles listed in Oldsmobile's records as previously repaired under Labor Operation T4676 were deleted from this campaign.
All vehicles listed on the dealer printout will require inspection, and as necessary, correction. Other suspect vehicles should be checked for campaign involvement by utilizing the Vehicle Information Service System (V.I.S.S.) for verification.
DEALER ACTION
If there is evidence of intentional disablement of the emission system, the dealer is to notify the vehicle owner of this condition and ask if he/she wants the system restored. Restoration cost is the responsibility of the owner.
Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of mileage, age of vehicle, or ownership from this time forward.
Whenever a vehicle subject to this campaign is taken into your new or used car inventory, or it is in your dealership for service, you are to ensure the campaign correction has been made before selling or releasing the vehicle.
Dealers are to contact owners of vehicles recently sold from your new or used vehicle inventory and arrange for the campaign correction to be performed.
SERVICE PROCEDURE
1. Raise and support the hood.
2. Write down the owner's preset radio stations and such other memory functions that can be recorded and reset later; then, with the ignition in the "off" position, disconnect the negative battery cable from the battery. If a memory retention device, such as Kent-Moore tool KS295A or BT 9027, is used, it is not necessary to record memory functions.
3. Do NOT disconnect the 11 pin IDI harness connector.
4. Remove the four bolts, ignition system assembly to cam housing.
5. Remove the ignition system assembly from the engine, turn it upside down and lay it on the engine using two bolts as "locator pins" through the cover into the cam housing on the "rear side" of the engine to hold the ignition system assembly in place.
NOTICE: If boots adhere to spark plugs, use tool J 36011 to remove by first twisting and then pulling upward on retainers. Reinstall boots and retainers on IDI housing secondary terminals, making sure that the spark plug connectors (item 9 in Figure 1) are in place. Boots and retainers must be in place on IDI housing secondary terminals prior to ignition system assembly installation or ignition system damage may result.
6. Remove the four housing to cover screws (item 4 in Figure 1) and remove the ignition coil housing (item 7) from the cover (item 1).
7. Remove the coil harness connectors (item 5) from the coils.
8. Refer to Figure 2, and inspect the two ignition coils for color of electrical tab. ignition Coils with black electrical tabs are to be replaced with new coils having yellow electrical tabs (from kit P/N 10457062). Coils with yellow electrical tabs do not require replacement. It should be rare to find a campaign vehicle in which one or both coils already have yellow tabs.
9. If necessary to replace one or both coils, remove the 'black tab' coil(s), the contacts(s), and the seal(s) from the cover (See Figure 1, item 6 and in View A, items 13 & 14).
10. Reinstall seal(s) (item 14 in Figure 1) to the housing.
11. Reinstall contact(s) (item 13) to the housing (use petroleum jelly to retain).
12. Install new "yellow tab" coil(s) to the cover, as required. Install coil harness connectors to both coils.
13. Reinstall the housing (item 7 in Figure 1) to the cover (item 1) with four screws (item 4); torque screws to 4 N.m (35 lb. in.).
14. Install the ignition system assembly to the engine while carefully aligning boots to the spark plug terminals.
15. Coat the four bolts, ignition system assembly to cam housing, with P/N 1052080 sealer (or equivalent). Install the bolts through the cover to the cam housing and torque to 20 N.m (1 5 lb. ft.).
NOTICE: If the above bolts are not coated with sealer prior to reinstallation, future removal of the bolts may strip the threads in the aluminum of the cam housings.
16. Reconnect the negative battery cable. In the interest of customer satisfaction, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected (not required if a memory retention tool was used).
17. Install a Campaign Identification Label.
CAMPAIGN IDENTIFICATION LABEL
Each label provides space to print the campaign number, and the five (5) digit dealer code of the dealer performing the campaign. Insert this information with a typewriter or ballpoint pen. When installing label, clean and dry the surface of the radiator support tie bar and apply the campaign label where it is readily visible.
PARTS INFORMATION
To ensure parts are obtained as soon as possible, order them from GM Service Parts Operations (GMSPO) on a C.I.O. order, with NO special instruction code, but order on an advise code (2). Use the following kit part number when ordering parts for this campaign:
Part Description Engine Usage Number Quantity/Vehicle ----------- ------------------ -------- --------------- Coil Kit Quad 4 (VIN D & A) 10457062 1 Kit
The Coil Kit contains two IDI Ignition Coils.
OWNER REIMBURSEMENT
Customers may request reimbursement for prior replacement of the ignition coil(s) due to misfire, rough idle, or a "no start" condition. Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity who performed the repair to receive reimbursement.
Claims for customer reimbursement on previously paid repairs are to be submitted according to the Warranty Claim Information instructions. Use the "Owner Reimbursement" labor operation and list all owner expenses concerning previous repairs in the net items column of the warranty claim.
NOTE: When a customer requests reimbursement, and the vehicle is still available, dealers are to inspect and, if necessary, replace ignition coils as called for in the SERVICE PROCEDURE of this bulletin. If owner's documentation indicates that both coils were replaced using coils from kit P/N 10457062 (or two P/N 10472748 coils), then Labor Op V6512 may be applied for and ft is not necessary to physically inspect the involved vehicle. Until the involved vehicle is confirmed to have the new coils installed (by inspection of the vehicle or the repair order, and any necessary replacement of coils performed), the campaign must remain open regardless of any reimbursement.
WARRANTY CLAIM INFORMATION
Submit claims using the labor-op listed below:
REPAIR PERFORMED FC LAB-OP LHRS -------------------------- ---- ------ ----- Inspect ignition Coils Only 96 V6510 0.3*
Inspect And Replace ignition Coil(s) 96 V6511 0.3*
Inspect Owner's Prior Repair Orders, 96 V6512 0.2* and Confirm That Two "Yellow Tab" Coils Had Been Installed (Two P/N 10472748 Coils Or Both Coils From Kit P/N 10457062)
Owner Reimbursement for Prior Repair 96 T4680 --
* .1 hour for clerical administration may be added to the above published labor hours.
NOTE: It should be rare that the "Inspect Only" labor operation is required. Also, ft should be rare to find an engine with one ignition coil with a yellow electrical tab and one coil with a black tab. It is necessary only to replace those ignition coils with black electrical tabs (see Figure 2).
Parts Allowance: Current dealer price, plus 30% allowance for handling.
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.
