CAMPAIGN: QUAD 4 IGNITION COIL INSPECT COIL CASE FOR CRACKS

Subject: EMISSION CAMPAIGN - 90-C-11 QUAD 4 IGNITION COIL

MODELS AFFECTED: 1988-90 GRAND AM AND 1990 GRAND PRIX WITH 2.3L ENGINE (VIN CODE D OR A)

General Motors has determined that some 1988-90 Grand Am models and 1990 Grand Prix 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 fails 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 1988-90 Grand Am models and 1990 Grand Prix models equipped with 2.3L (VIN Code D or A) Engines (options LD2 or LGO) within the following VIN breakpoints:

Up To And Carline Year RPO/VIN Emission Plant Beginning Including --------- ---- ------ --------- ------- --------- --------- Grand Am 1988 LD2/D Federal Lansing JC600002 JC835384 Grand Am 1988 LD2/D California Lansing JC615231 JC834746 Grand Am 1989 LD2/D Federal Lansing KC600001 KC846424 Grand Am 1989 LD2/D California Lansing KC600005 KC845961 Grand Am 1989 LGO/A Federal Lansing KC780903 KC819593 Grand Am 1989 LGO/A California Lansing KC806546 KC813119 Grand Am 1990 LD2/D Federal Lansing LC200002 LC355438 Grand Am 1990 LD2/D California Lansing LC200024 LC335448 Grand Am 1990 LGO/A Federal Lansing LC200001 LC354769 Grand Am 1990 LGO/A California Lansing LC200127 LC354515 Grand Prix 1990 LD2/D Federal Fairfax LF200003 LF297772 Grand Prix 1990 LD2/D California Fairfax LF218878 LF322585

NOTICE: Vehicles listed in Pontiac'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 (VISS) for verification.

Involved vehicles have been identified by Vehicle Identification Number Computer Listings. Computer listings contain the complete Vehicle Identification Number, owner name and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data furnished will enable dealers to follow-up with owners involved in this campaign.

These listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

OWNER NOTIFICATION

Owners will be notified of this campaign on their vehicles by Pontiac Division (see copy of Owner Letter included with this bulletin).

DEALER CAMPAIGN RESPONSIBILITY

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 service all vehicles subject to this campaign 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 vehicle inventory, or it is in your dealership for service in the future, you should take the steps necessary to be sure the campaign correction has been made before reselling or releasing the vehicle.

Owners of vehicles recently sold from your new or used vehicle inventory are to be contacted by the dealer, and arrangements made to make the required modification according to instructions contained in this bulletin.

PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure that these parts are obtained as soon as possible, they should be ordered on a C.I.O. order with no special instruction code, but on advise code (2).

Quantity Description Part Number Per Vehicle ----------- ------------ ------------ Coil Kit 10457062 1

It is expected that almost 100% coil replacement will be performed on involved vehicles, hence kits should be ordered based on the number of vehicles listed on the VIN printout sent to dealers with involved vehicles.

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, 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 (15 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 batter was disconnected (not required if a memory retention tool was used).

17. Install a Campaign Identification Label.

CAMPAIGN IDENTIFICATION LABEL

Each vehicle modified in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the campaign number, the five digit dealer code of the dealer performing the campaign service, and the date the vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. Install the label only on a clean, dry surface of the radiator baffle where it is readily visible. (Additional campaign labels are available on stationery order as Form 7901-709).

CLAIM INFORMATION

A separate repair order must be used for each vehicle. A completed warranty claim is to be kept as a permanent record of completion.

DEALERS SHOULD SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS:

*Other Failure Labor Labor Labor Operation Code Operation Hours Hours --------------------------- ------- --------- ------ ------ Inspect Ignition Coils Only 96 V6510 0.3 0.1 Inspect And Replace Ignition 96 V6511 0.3 0.1 Coils Inspect Owner's Prior Repair 96 V6512 0.2 0.1 Orders, 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 96 T4680 --- --- Repair

NOTICE: It should be rare that the "Inspect Only" labor operation is required. Also, it 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).

* In addition, dealerships will receive 0.1 hours credit for dealer adminis- trative services associated with this campaign. The 0.1 hours allowance is to be entered in the "Other Labor Hours" field with each campaign repair listed for credit. This entry will not require authorization.

FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION.

Parts required are to be listed in your warranty claim in the normal manner. Parts will be credited at dealer net plus 30% dealer handling allowance. Dealers will be credited via Warranty Document or Terminal Transmission, whichever is their normal method of submission for payment. Claim must contain all information required and should list the labor operation as outlined.

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 unre- imbursed repair expenses, a description of the repair, the date of the repair, and the person or entity who performed the repair to receive reimbursement.

Customer claims for reimbursement on previously paid repairs to replace ignition coil(s) are to be submitted in the following manner: Use the special "Owner Reimbursement" labor operation listed under the Claim Information Section of this bulletin. Reimbursement amounts of $300.00 or less can be processed by the dealer. If the amount exceeds $300.00, an Owner Reimbursement Form 7201-039 (Rev. 6/88) must be forwarded to and processed by the Zone Office.

NOTICE: 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 Operation V6512. may be applied for and it 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.

RECORDING COMPLETION

Repairs submitted for vehicles not involved in the campaign will not be paid.

Campaign completion will be recorded from "PROPERLY COMPLETED AND PAID WARRANTY CLAIMS." Owners are being asked to present the owner reply card for identification to their dealer at the time they bring in their vehicle to have the campaign performed.

Dear Pontiac Owner:

This notice has been sent to inform you that Pontiac Division is initiating an emission recall that includes your vehicle.

REASON FOR RECALL

General Motors has determined that certain 1988-90 Pontiac Grand Am models and 1990 Grand Prix models equipped with 2.3L engines may develop cracks in the case of the IDI (Integrated Direct Ignition) coil(s) at 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 fails completely.

WHAT WE WILL DO

To prevent this condition from occurring, your dealer will inspect your vehicle's ignition coils and, if necessary, replace the coils. This service will be provided for you at no charge.

WHAT YOU SHOULD DO

Please contact your Pontiac dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer and parts are available. Please ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

You may have your vehicle serviced at the authorized Pontiac dealer of your choice.

If your Pontiac vehicle previously had the ignition coil(s) replaced for a misfire, rough idle or "no start" condition, and you paid for all or part of the repair, you may request reimbursement through your Pontiac dealer. When doing so, you should present the dealer with original documentation which reasonably confirms the amount of unreimbursed repair expenses due to replacement/repair of the ignition coil(s), date of the repair, and the person or entity performing the repair. You should also have your dealer inspect your vehicle to see if the campaign work still needs to be performed, regardless of prior repairs for a misfire, rough idle or "no start" condition.

The enclosed Owner Identification Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the necessary inspection/correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage paid reply card and returning it to us. Should your dealer not schedule a service date within a reasonable time, you should contact the Pontiac Customer Assistance Center by calling: 1-800-762-2737.

If your dealer and the Customer Assistance Center are unable to remedy this condition within a reasonable time, you may wish to advise the Environmental Protection Agency, at the following address: Director, Manufacturer's Operations Division (EN-340F), United States Environmental Protection Agency, 401 M Street, S.W., Washington, DC 20460.

To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if this recall work is not accomplished.

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

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.