ENGINE EXCHANGE PROGRAM 3.4L OVERHEAD VALVE. Pontiac Firebird 1993

REVISION 01/24/94

THIS BULLETIN CANCELS THE 1993 MODEL YEAR ENGINE EXCHANGE PROGRAM AND INITIATES THE 1994 MODEL YEAR ENGINE EXCHANGE PROGRAM. PREVIOUS DIVISIONAL PUBLICATION NUMBERS WERE: CHEVROLET 93-94-6 PONTIAC 93-6-26 GM OF CANADA 93-6-111 --------------------------------------------------------------------- SUBJECT: ENGINE EXCHANGE PROGRAM FOR 3.4L (L32) OVERHEAD VALVE ENGINE

MODELS: 1994 CHEVROLET CAMARO 1994 PONTIAC FIREBIRD

THE 1993 ENGINE EXCHANGE PROGRAM FOR 3.4L (L32) ENGINES EXPIRED AT THE END OF THE 1993 MODEL YEAR.

A 1994 MODEL YEAR ENGINE EXCHANGE PROGRAM IS NOW INITIATED TO OBTAIN IMMEDIATE ENGINEERING AND MANUFACTURING FEEDBACK ON THE NEW 3.4L OVERHEAD VALVE V6, AND IS IN EFFECT UNTIL SEPTEMBER 1, 1994.

THIS EXCHANGE PROGRAM WILL BE ADMINISTERED BY THE MARKETING DIVISIONS' TECHNICAL ASSISTANCE GROUPS. THE FOLLOWING EXPLAINS THE REQUIREMENTS REGARDING SERVICEABLE AND NON-SERVICEABLE ITEMS, WARRANTY CLAIMS PROCESSING PROCEDURES AND SHIPPING INSTRUCTIONS. CHEVROLET DEALERS: THIS BULLETIN SHOULD BE FILED IN THE "SPECIAL EXCHANGE POLICY PROCEDURES" MANUAL.

IF YOU REQUIRE AN EXCHANGE ENGINE ASSEMBLY, FOLLOW THE PROCEDURE BELOW.

THE FOLLOWING COMPONENTS ARE **NOT** TO BE REMOVED:

CYLINDER BLOCK CAMSHAFT OIL SEALS HARMONIC BALANCER CYLINDER HEADS OIL PUMP CYLINDER HEAD GASKETS CRANK SPROCKET LOWER INTAKE CRANKSHAFT PISTON ASSEMBLY (PISTONS/RODS/RINGS)

A. ENGINE COMPONENTS WHICH MAY BE SERVICED: --------------------------------------- NOTE: ANY DEFICIENT ENGINE COMPONENT ON THE FOLLOWING LIST SHOULD BE REPAIRED ACCORDING TO SERVICE PROCEDURES IN THE APPLICABLE SERVICE MANUALS.

1. BRACKETS: REAR LIFT BRACKET (AUTOMATIC AND MANUAL), AND ACCELERATOR CABLE BRACKET.

2. WATER PUMP: WATER PUMP AND RELATED GASKETS, WATER OUTLET, THERMOSTAT, WATER INLET AND GASKET, COOLANT BYPASS PIPE AND HOSE.

3. VACUUM TUBES: PCV HOSES AND RELATED COMPONENTS. TRANSMISSION MODULATOR PIPE.

4. IGNITION: SPARK PLUGS, LEFT AND RIGHT HAND WIRING HARNESSES, IGNITION COIL PACK.

5. ELECTRICAL KNOCK SENSOR, COOLANT LEVEL SENSOR, COOLANT COMPONENTS: TEMPERATURE SENSOR, CRANK TIMING SENSOR, MAP SENSOR, OIL PRESSURE SENSOR, OXYGEN SENSORS, TP SENSOR, IAC VALVE, AND CAM TIMING SENSOR.

6. UPPER INTAKE: PLENUM AND RELATED 0-RING SEAL, FUEL RAIL AND INJECTORS, FUEL LINES, FUEL PRESSURE REGULATOR AND HOSE, EGR TUBE, THROTTLE BODY AND RELATED MOUNTING PARTS.

7. INJECTOR WIRING HARNESS

8. BLOCK HEATER (IF APPLICABLE)

9. FLYWHEEL ASSEMBLY

10. CLUTCH AND PRESSURE PLATE ASSEMBLY

11. EXHAUST MANIFOLDS AND RELATED GASKETS, A.I.R. PIPES AND CHECK VALVES.

12. OIL PAN, OIL DIPSTICK AND TUBE, OIL CAP, OIL FILTER AND OIL COOLER.

13. COMPLETE ACCESSORY DRIVE AND SUPPORTING BRACKETS, TO INCLUDE STARTER, GENERATOR, A/C COMPRESSOR, POWER STEERING PUMP, AND ALL ATTACHING PARTS.

14. STARTER MOTOR

B. ENGINE EXCHANGE: --------------- ANY DEFICIENT ENGINE COMPONENT NOT INCLUDED IN PARAGRAPH (A) ABOVE MAY NECESSITATE AN EXCHANGE ENGINE.

C. EXCHANGE PROCEDURE: ------------------ ONCE THE ABOVE PRELIMINARY DIAGNOSIS IS MADE AND AN EXCHANGE UNIT IS DEEMED NECESSARY, CALL THE MARKETING DIVISION'S TECHNICAL ASSISTANCE GROUP. TECHNICAL ASSISTANCE WILL ARRANGE TO SHIP AN EXCHANGE ENGINE TO YOUR DEALERSHIP AND PROVIDE YOUR DEALERSHIP WITH A TECHNICAL ASSISTANCE CASE REFERENCE NUMBER.

TO INCREASE THE EFFECTIVENESS OF THE PROGRAM, THE ENGINE REMOVED FROM THE VEHICLE MUST BE RETURNED IMMEDIATELY **(NO LATER THAN ONE (1) WEEK AFTER THE RECEIPT OF THE REPLACEMENT ENGINE).**

FAILURE TO RETURN THE FAILED ENGINE ASSEMBLY WILL RESULT IN THE

DEALERSHIP BEING BILLED THE VALUE OF THE EXCHANGED ENGINE ($3000.00) -------------------------------------------------------------------- PLUS AN ADMINISTRATIVE CHARGE. -----------------------------

ALL PROCEDURAL STEPS MUST BE FOLLOWED TO ENSURE THAT YOUR DEALERSHIP IS NOT BILLED FOR THIS ENGINE. THE REMOVED UNIT MUST BE RETURNED COMPLETE AS REMOVED FROM THE VEHICLE IN THE CONTAINER PROVIDED, WITHOUT EXAMINATION OF THE UNIT OTHER THAN AS DESCRIBED IN PARAGRAPH (A) ABOVE. ENGINE DRESS ON THE REMOVED UNIT MUST REMAIN THE SAME AS THE REPLACEMENT ENGINE SHIPPED. DEALERSHIPS RETURNING ENGINES HAVING BEEN PARTIALLY DISASSEMBLED WILL BE JUDGED AS VIOLATING THIS PROCEDURE AND AS SUCH WILL BE SUBJECT TO BEING BILLED FOR ALL MATERIALS SUPPLIED.

THE EXCHANGE UNIT WILL BE SHIPPED WITH MINIMUM QUANTITY OF OIL; ADD OIL PER SPECIFICATIONS.

THE EXCHANGE UNIT WILL HAVE AN ENVELOPE ATTACHED TO IT. THIS ENVELOPE WILL CONTAIN:

- RETURN SHIPPING LABEL (FREIGHT IS PREPAID). - LEAK IDENTIFICATION CHARTS.

NOTE: AN EXCHANGE ENGINE WILL BE SHIPPED WITHIN TWENTY-FOUR (24) HOURS OR ONE (1) WORKING DAY. THE ENGINE PLANT WILL MAKE EVERY EFFORT TO ENSURE DELIVERY TO DEALER WITHIN FORTY-EIGHT (48) HOURS OR TWO (2) WORKING DAYS. IN CANADA, ALLOW NINETY-SIX (96) HOURS OR FOUR (4) WORKING DAYS FOR DELIVERY TO THE DEALER.

D. PREPARATION FOR SHIPPING: ------------------------ VISUALLY CHECK TO ESTABLISH THAT ALL FLUID LEVELS ARE WITHIN THE NORMAL OPERATING RANGE. IF NOT, DRAIN AND MEASURE THE OIL AND COOLANT FROM THE DEFICIENT ENGINE. RECORD THE OIL AND COOLANT LEVELS ON THE REPAIR ORDER. REPLACE THE DRAIN PLUG. ----------------------

REMOVE THE ENGINE AS OUTLINED IN THE 1994 SERVICE MANUAL. REMOVE ALL PLASTIC SHIPPING PLUGS AND COVERS FROM THE EXCHANGED ENGINE AND INSTALL THEM ON THE ENGINE REMOVED FROM THE VEHICLE.

IF ENGINE LEAKS FLUID, MARK THE AREA ON THE ENGINE. ALSO, MARK THE AREA WITH A RED PEN ON THE ILLUSTRATIONS PROVIDED WITH THE EXCHANGE ENGINE. WRITE THE TECHNICAL ASSISTANCE CASE REFERENCE NUMBER ON THE ILLUSTRATION SHEET AS WELL.

REPACK THE REMOVED UNIT INTO THE REPLACEMENT ENGINE'S SHIPPING CONTAINER.

PLACE THE LEAK IDENTIFICATION CHARTS AND A LEGIBLE COPY OF THE REPAIR ORDER IN THE ORIGINAL ENVELOPE AND ATTACH IT TO THE RETURN ENGINE.

E. SHIPPING INSTRUCTIONS: --------------------- PLACE THE SHIPPING LABEL OVER THE ORIGINAL LABEL ON THE SHIPPING CONTAINER. THE BILL OF LADING AND CUSTOM PAPERS, PROVIDED WITH THE EXCHANGE ENGINE, ARE THE ONLY DOCUMENTS REQUIRED TO RETURN SHIP THE REMOVED ENGINE.

**NOTE: THE SAME CARRIER, WHOSE NAME IS INDICATED ON THE BILL OF LADING, SHOULD BE USED TO SHIP THE RETURN ENGINE.**

ALL REQUIRED DATA ON THE BILL OF LADING WILL BE COMPLETE, EXCEPT FOR THE DATE AND CARRIER SIGNATURE. 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 TWO (2) 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 TRUCK FREIGHT COLLECT TO:

GENERAL MOTORS LAREDO 2301 SCOTT STREET LAREDO, TEXAS 78040

ATTN: JAIME RAMOS

F. WARRANTY CLAIMS PROCESSING PROCEDURE: ------------------------------------ UPON COMPLETION OF THE REPAIR, A WARRANTY CLAIM IS TO BE SUBMITTED TO THE APPLICABLE MARKETING DIVISION.

LABOR OPERATION PART LABOR/OTHER NUMBER DESCRIPTION ALLOWANCE HOURS --------- ----------- --------- ----------- J1880 REPLACE ENGINE ASSEMBLY $404.65 USE APPLICABLE HOURS PUBLISHED IN THE LABOR TIME GUIDE.

ADD TIME: WITH AIR CONDITIONING USE APPLICABLE HOURS PUBLISHED IN THE LABOR TIME GUIDE.

WITH LOCKING WHEEL USE APPLICABLE HOURS COVERS/NUTS PUBLISHED IN THE LABOR TIME GUIDE.

THE AMOUNT IDENTIFIED IN THE "PART ALLOWANCE" COLUMN ABOVE REPRESENTS 40 PERCENT OF THE DIFFERENCE BETWEEN THE CURRENT GMSPO DEALER NET PRICE AND THE ENGINE RETURN CREDIT (CORE ALLOWANCE). THIS AMOUNT IS TO BE PLACED IN THE NET AMOUNT COLUMN OF THE CLAIM.

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

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF THE ENGINE WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS REGARDING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT YOUR MARKETING DIVISION'S TECHNICAL ASSISTANCE GROUP.

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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.