SPECIAL POLICY ADJUSTMENT COOLANT LOSS, LOW COOLANT

REVISION: 11/13/95

THIS BULLETIN IS BEING REVISED TO INFORM "GM OF CANADA" AND "NAES" DEALERS THAT THEY ARE NOT AUTHORIZED TO UTILIZE THIS SERVICE BULLETIN. **********************************************************************

REVISION: 01/29/96

THIS BULLETIN IS BEING REVISED TO INCLUDE VALVE GUIDE SEALS NEEDED FOR CYCLINDER HEAD REPLACEMENT AND TO CLARIFY SERVICE INFORMATION REGARDING GASKETS AND THE CAM CARRIER ASSEMBLY. PLEASE DISCARD BULLETIN 57-61-26 (SECTION - SPECIAL POLICY). **********************************************************************

SUBJECT: SPECIAL POLICY ADJUSTMENT - COOLANT LOSS, LOW COOLANT LAMP ON, VISIBLE COOLANT LEAKAGE, OR COOLANT ODOR, CAUSED BY A CRACKED CYLINDER HEAD

MODELS: 1992-93 BUICK SKYLARK 1992-93 OLDSMOBILE ACHIEVA 1992-93 PONTIAC GRAND AM WITH 2.3L QUAD OHC ENGINE (VIN ENGINE CODE 3 - RPO L40) (SINGLE OVERHEAD CAM ONLY)

IMPORTANT: "GM OF CANADA" AND "NAES" DEALERS ARE NOT AUTHORIZED TO UTILIZE THIS SERVICE BULLETIN.

THIS SPECIAL POLICY ADJUSTMENT APPLIES ONLY TO THOSE VEHICLES BUILT THROUGH APRIL 1993 AND ONLY TO THOSE PRODUCED WITH RPO L40 ENGINES.

PLANT DIVISION MY MODEL CODE BEGINNING VIN ENDING VIN

BUICK 1992 SKYLARK C NC600001 NC660609 1993 SKYLARK C PC250001 PC294508

OLDSMOBILE 1992 ACHIEVA M NM400001 NM477457 1993 ACHIEVA M PM000001 PM034139

PONTIAC 1992 GRAND AM C NC200001 NC303621 1992 GRAND AM M NM000001 NM104947 1993 GRAND AM C PC700001 PC785617 1993 GRAND AM M PM500001 PM598811

CONDITION:

SOME CUSTOMERS MAY COMMENT ABOUT ENGINE COOLANT LOSS, A LOW COOLANT LAMP, OR AN ODOR OF ENGINE COOLANT IN THE VEHICLE.

CAUSE:

SOME 1992-93 L40 ENGINES MAY DEVELOP A CRACKING CONDITION OF THE CYLINDER HEAD. THE CRACKING OCCURS ON THE OUTSIDE OF THE CYLINDER HEAD CAUSING AN EXTERNAL COOLANT LEAK THAT MAY CAUSE THE OWNER TO COMMENT ABOUT THE CONDITIONS NOTED ABOVE. THE CRACKING OCCURS IN SPECIFIC AREAS OF THE CYLINDER HEAD AND MAY LEAVE A COOLANT DEPOSIT ON THE REAR (EXHAUST SIDE) OF THE CYLINDER HEAD THAT MAY INDICATE LEAKAGE FROM THESE CRACKS. (SEE FIGURE 1)

SPECIAL POLICY ADJUSTMENT THIS SPECIAL POLICY COVERS THE CONDITION DESCRIBED ABOVE FOR A PERIOD OF SEVEN YEARS OR 100,000 MILES (160,000 KM), WHICHEVER OCCURS FIRST, FROM THE DATE THE VEHICLE WAS ORIGINALLY PLACED IN SERVICE, REGARDLESS OF OWNERSHIP.

THE REPAIRS WILL BE MADE AT NO CHARGE TO THE OWNER. THIS SPECIAL POLICY APPLIES ONLY TO REPAIRS REQUIRING CYLINDER HEAD REPLACEMENT AS A RESULT OF CYLINDER HEAD CRACKING THAT RESULTS IN AN ENGINE COOLANT LEAK. IT DOES NOT COVER OTHER CONDITIONS THAT MAY NECESSITATE REPLACEMENT OF THE CYLINDER HEAD.

PARTS INFORMATION WHENEVER ORDERING PARTS FOR A CYLINDER HEAD REPLACEMENT, REFER TO THE FOLLOWING PART NUMBERS:

PART PART QUANTITY NUMBER DESCRIPTION PER VEHICLE

24574472 HEAD, 1 CYLINDER

12356554 GASKET KIT, 1 CYLINDER HEAD

03634621 SEALER, 2 PELLETS PER COOLING VEHICLE SYSTEM- PACKAGE OF 6 PELLETS

12345612 BULK ENGINE 4.25 QUARTS OIL 5W30 (4.02 LITERS)

25014233 FILTER, 1 ENGINE OIL PF1225

1052754 BULK ENGINE 5 QUARTS COOLANT (4.73 LITERS)

22531217 SEAL, VALVE GUIDE 1 SET OF 8

SERVICE INFORMATION MANY OF THE GASKETS AND SEALS ON THE QUAD OHC ENGINE ARE REUSABLE. THE REUSABLE GASKETS THAT YOU WILL ENCOUNTER DURING CYLINDER HEAD REPLACEMENT ARE THE INNER AND OUTER TIMING CHAIN COVER GASKETS. THE TIMING CHAIN COVER GASKETS SHOULD BE REUSED IF THEY ARE NOT TORN OR DAMAGED. IN ADDITION, THE CAM CARRIER SHOULD NOT BE SEPARATED DURING THIS PROCEDURE, THEREFORE THERE SHOULD BE NO NEED FOR CAM CARRIER SEALS.

OWNER NOTIFICATION OWNERS WILL BE NOTIFIED OF THIS SPECIAL POLICY BY (BUICK / OLDSMOBILE / PONTIAC) DIVISION (SEE COPY OF THE OWNER LETTER INCLUDED WITH THIS BULLETIN).

OWNER REIMBURSEMENT CUSTOMER CLAIMS FOR REIMBURSEMENT ON PREVIOUSLY PAID REPAIRS TO REPLACE THE CYLINDER HEAD AS A RESULT OF CYLINDER HEAD CRACKING THAT RESULTED IN AN ENGINE COOLANT LEAK, ARE TO BE SUBMITTED BY NOVEMBER 1, 1996 (THIS TIME LIMITATION MAY BE LONGER DEPENDING ON THE LAW IN SOME STATES, SUCH AS CALIFORNIA, CONNECTICUT, VIRGINIA, AND WISCONSIN). REPAIRS MUST HAVE OCCURRED WITHIN SEVEN YEARS OF THE DATE THE VEHICLE WAS ORIGINALLY PLACED IN SERVICE, OR 100,000 MILES (160,000 KM), WHICHEVER OCCURS FIRST. OWNERS (AND/OR PRIOR OWNERS) MUST SUBMIT ORIGINAL DOCUMENTATION WHICH REASONABLY CONFIRMS THE AMOUNT OF UNREIMBURSED REPAIR EXPENSE(S), A DESCRIPTION OF THE REPAIR, DATE OF THE REPAIR, AND THE PERSON OR ENTITY PERFORMING THE REPAIR. CUSTOMERS FROM THE STATES OF CALIFORNIA, CONNECTICUT, VIRGINIA, AND WISCONSIN MUST SUBMIT REQUESTS FOR REIMBURSEMENT DIRECTLY TO (BUICK / OLDSMOBILE / PONTIAC) PER INSTRUCTIONS IN THE OWNER LETTER.

DIAGNOSIS 1. IF ANY OF THE ABOVE CONDITIONS ARE NOTED, FIRST INSPECT VEHICLE PER SECTION 6B IN THE SERVICE MANUAL. IF NO OTHER CAUSE IS FOUND FOR THIS CONDITION, PROCEED WITH STEP 2.

2. REMOVE THE IGNITION COIL HOUSING COVER AND INSPECT REAR (EXHAUST SIDE) OF THE CYLINDER HEAD FOR VISIBLE CRACKS AND A BUILDUP OF COOLANT DEPOSITS. (SEE FIGURE 1)

3. IF ANY CRACKS ARE FOUND IN THE CYLINDER HEAD, REPLACE THE CYLINDER HEAD AS DESCRIBED BELOW.

SERVICE PROCEDURE INSTALL A REVISED CYLINDER HEAD USING THE PROCEDURE OUTLINED IN SERVICE BULLETIN 276113 REGARDING CYLINDER HEAD TIGHTENING AND CLEANING PROCEDURE. THE REVISED CYLINDER HEAD GM P/N 24574472 WITH CASTING NUMBER 24574468 MAY BE IDENTIFIED BY THE APPEARANCE DIFFERENCES ILLUSTRATED IN FIGURE 2.

IMPORTANT: CYLINDER HEAD TIGHTENING PROCEDURE (THIS IS THE SAME TIGHTENING PROCEDURE AS NOTED IN SERVICE BULLETIN 276113.)

A. TIGHTEN THE BOLTS TO THE FOLLOWING N.M (LB. FT) SPECIFICATION IN SEQUENCE: 1. BOLTS 1 THROUGH 8 (LONG BOLTS ): 40 N.M (30 LB. FT.)

2. BOLTS 9 AND 10 (SHORT BOLTS): 35 N.M (26 LB. FT.).

B. THEN TURN ALL 10 BOLTS 90 DEGREES (1/4 TURN) IN SEQUENCE USING J36660 TOOL.

NOTICE: NEVER USE ABRASIVE PADS TO CLEAN THE CYLINDER HEAD OR BLOCK SURFACES. AN ABRASIVE PAD MAY DAMAGE THE CYLINDER HEAD AND THE BLOCK. ABRASIVE PADS WILL PRODUCE A FINE GRIT THAT THE OIL FILTER WILL NOT BE ABLE TO REMOVE FROM THE OIL. THIS GRIT IS ABRASIVE AND HAS BEEN KNOWN TO CAUSE INTERNAL ENGINE DAMAGE. ALSO, ABRASIVE PADS MAY ROUND THE CYLINDER HEAD EDGES OR REMOVE ENOUGH METAL DURING CLEANING TO AFFECT CYLINDER HEAD FLATNESS, BOTH OF WHICH ARE KNOWN TO AFFECT THE CYLINDER HEAD GASKET SEAL.

DISPOSITION OF REPLACED CYLINDER HEADS:

NOTICE: THERE IS A CORE CHARGE ON THE CYLINDER HEADS FROM GMSPO, WHEN THE CYLINDER HEAD IS REMOVED FROM THE VEHICLE IT WILL NEED TO BE RETURNED TO RECEIVE THE CORE CHARGE IN ACCORDANCE WITH GMSPO PROCEDURES. THE CRACKED CYLINDER HEAD BEING RETURNED MUST BE MARKED WITH THE LAST EIGHT DIGITS OF THE VEHICLE VIN. THE MARKING SHOULD BE MADE WITH A YELLOW PAINT OR PERMANENT FELT TIP MARKER ON ANY FLAT AREA OF THE CYLINDER HEAD.

WARRANTY INFORMATION FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

COMPLAINT FAILURE LABOR CODE CODE PROCEDURE OPERATION LABOR HOURS

MK 95 HEAD, CYLINDER- T2140 9.0 REPLACE

ADD: TO CLEAN .2 PARTS ON VEHICLES OVER 30,000 MILES/ 48,000 KM

ADD: FOR VEHICLES .1 WITH LOCKING WHEEL COVERS OR WHEEL NUTS

MK 95 REIMBURSEMENT FOR T2141 .2* PREVIOUS CYLINDER ADMINISTRATIVE HEAD REPLACEMENTS LABOR ALLOWANCE

* FOLLOW SUBMISSION PROCEDURES AS (DIVISIONALLY SPECIFIC INSTRUCTIONS).

IMPORTANT: T2141 IS NOT TO BE USED FOR RESIDENTS OF THE STATES OF CALIFORNIA, CONNECTICUT, VIRGINIA, OR WISCONSIN. REQUESTS FROM THESE RESIDENTS MUST BE SUBMITTED IN WRITING TO (BUICK / OLDSMOBILE / PONTIAC) DIVISION. SEE OWNER LETTER FOR INSTRUCTION.

FIGURE 1- CYLINDER HEAD AREAS THAT MAY EXHIBIT CRACKS OR COOLANT DEPOSITS.

LEGEND:

1. CRACKS 2. COOLANT DEPOSITS

FIGURE 2- COMPARISON VIEW OF REVISED CYLINDER HEAD

LEGEND:

VIEW -A- ORIGINAL CYLINDER HEAD VIEW -B- REVISED CYLINDER HEAD WITH ADDITIONAL MATERIAL SHOWN IN SHADED AREAS.

OWNER LETTER

DEAR (BUICK / OLDSMOBILE / PONTIAC) OWNER:

AS THE OWNER OF A 1992 OR 1993 (BUICK SKYLARK / OLDSMOBILE ACHIEVA / PONTIAC GRAND AM) EQUIPPED WITH A 2.3L QUAD OHC (RPO CODE L40, VIN ENGINE CODE 3) ENGINE, YOUR SATISFACTION WITH OUR PRODUCT IS OF UTMOST CONCERN TO US. YOUR VEHICLE WAS PROVIDED WITH A NEW VEHICLE WARRANTY WHICH COVERS CERTAIN PARTS OF YOUR VEHICLE FOR A SPECIFIED PERIOD. THESE WARRANTIES ARE OF CONSIDERABLE VALUE TO YOU IF YOU SHOULD EXPERIENCE PROBLEMS WITH YOUR VEHICLE.

CONDITION THIS LETTER IS INTENDED TO MAKE YOU AWARE THAT SOME 1992 AND 1993 (BUICK SKYLARK / OLDSMOBILE ACHIEVA / PONTIAC GRAND AM) MODELS WITH 2.3L QUAD OHC (RPO CODE L40, VIN ENGINE CODE 3) ENGINES MAY DEVELOP A CRACKING CONDITION OF THE CYLINDER HEAD THAT ALLOWS COOLANT TO LEAK FROM THE CYLINDER HEAD. EARLY EVIDENCE OF THIS WOULD BE A LOSS OF COOLANT IN THE COOLANT RESERVOIR AND COOLANT DEPOSITS ON THE EXTERIOR OF THE CYLINDER HEAD. THESE MAY BE COMBINED WITH THE ODOR OF COOLANT FROM THE ENGINE COMPARTMENT.

ACTION (BUICK / OLDSMOBILE / PONTIAC) DIVISION IS THEREFORE TAKING THE FOLLOWING ACTION:

WE ARE PROVIDING OWNERS WITH SPECIAL COVERAGE. IF THE ABOVE MENTIONED CONDITION OCCURS WITHIN SEVEN (7) YEARS OF THE DATE THE VEHICLE WAS ORIGINALLY PLACED IN SERVICE OR 100,000 MILES (160,000 KM), WHICHEVER OCCURS FIRST, THE CONDITION WILL BE REPAIRED FOR YOU AT NO CHARGE.

THIS IS NOT A RECALL CAMPAIGN. DO NOT TAKE YOUR VEHICLE TO YOUR (BUICK / OLDSMOBILE / PONTIAC) DEALER/RETAILER AS A RESULT OF THIS LETTER UNLESS YOU BELIEVE THAT YOUR VEHICLE HAS THE CONDITION AS DESCRIBED ABOVE.

REIMBURSEMENT

(STATEMENT FOR ALL STATES EXCEPT AS SHOWN BELOW.)

IF YOU HAVE ALREADY PAID FOR SOME OR ALL OF THE COST TO HAVE THE CYLINDER HEAD REPLACED AND YOUR MILEAGE AND IN SERVICE TIME WAS LESS THAN SEVEN (7) YEARS AND 100,000 MILES (160,000 KM), YOU SHOULD CONTACT YOUR (BUICK / OLDSMOBILE / PONTIAC) DEALER/RETAILER SERVICE DEPARTMENT TO SEEK REIMBURSEMENT. PLEASE PROVIDE YOUR RETAILER WITH YOUR ORIGINAL PAID RECEIPTS OR INVOICES VERIFYING THE REPAIR, THE AMOUNT CHARGED, PROOF OF PAYMENT, AND THE DATE OF PAYMENT OF THOSE CHARGES BY NOVEMBER 1, 1996.

(STATEMENT FOR CALIFORNIA, CONNECTICUT, VIRGINIA, AND WISCONSIN)

IF YOU HAVE ALREADY PAID FOR SOME OR ALL OF THE COST TO HAVE A CYLINDER HEAD REPLACED AND YOUR MILEAGE AND IN SERVICE TIME WAS LESS THAN SEVEN (7) YEARS AND 100,000 MILES (160,000 KM), YOU SHOULD WRITE (DIVISIONALLY SPECIFIC ADDRESS) TO SEEK REIMBURSEMENT. PLEASE PROVIDE YOUR ORIGINAL PAID RECEIPTS OR INVOICES VERIFYING THE REPAIR, THE AMOUNT CHARGED, PROOF OF PAYMENT, AND THE DATE OF PAYMENT OF THOSE CHARGES. THIS INFORMATION MUST BE PROVIDED WITHIN TWO (2) YEARS AFTER THE DATE ON WHICH YOU PAID FOR THE REPAIR.

CONTACTING YOUR DEALER/RETAILER

REPAIRS AND ADJUSTMENTS QUALIFYING UNDER THIS SPECIAL COVERAGE MUST BE PERFORMED BY A (BUICK / OLDSMOBILE / PONTIAC) DEALER/RETAILER. REPAIRS MAY BE PERFORMED BY ANY AUTHORIZED (BUICK / OLDSMOBILE / PONTIAC) DEALER/RETAILER. YOU MAY WANT TO CALL THE SERVICE DEPARTMENT AT THE DEALER/RETAIL FACILITY TO FIND OUT HOW LONG THEY WILL NEED TO HAVE THE VEHICLE SO THAT YOU MAY SCHEDULE THE REVIEW AT THE MOST CONVENIENT TIME FOR YOURSELF. THIS WILL ALSO ALLOW YOUR DEALER/RETAILER TO ORDER PARTS IF THEY ARE NOT IN STOCK. KEEP THIS LETTER WITH YOUR OTHER IMPORTANT GLOVEBOX LITERATURE FOR FUTURE REFERENCE.

HOW LONG WILL IT TAKE TO REPLACE THE CYLINDER HEAD?

THE TIME NEEDED TO REPLACE A CYLINDER HEAD IS ABOUT NINE (9) HOURS. DUE TO SCHEDULING AND PROCESSING TIME YOUR DEALER/RETAILER MAY NEED TO KEEP YOUR CAR OVERNIGHT. WE REGRET ANY INCONVENIENCE THAT YOU MAY EXPERIENCE: HOWEVER, WE HAVE TAKEN THIS ACTION IN THE INTEREST OF YOUR CONTINUED SATISFACTION WITH OUR PRODUCTS.

(BUICK / OLDSMOBILE / PONTIAC) DIVISION GENERAL MOTORS CORPORATION

FIGURES: 2 ATTACHMENTS: 0

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.

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