CAMPAIGN:ENGINE MAIN BEARING CAP BOLTS MAY BREAK

GENERAL MOTORS HAS DETERMINED THAT SOME 1983 2000 MODELS EQUIPPED WITH 1.8 LITER ELECTRONIC FUEL INJECTION/OVERHEAD CAM ENGINES MAY HAVE BEEN ASSEMBLED WITH INCORRECT ENGINE MAIN BEAING CAP BOLTS. IN SOME CASES, THE MAIN BEARING CAP BOLTS COULD BREAK. THIS COULD CAUSE EXTENSIVE DAMAGE TO THE ENGINE CRANKSHAFT. TO PREVENT THIS FROM OCCURING, DEALERS ARE TO INSPECT VEHICLES FOR SPECIFIC ENGINE IDENTIFICATION AND, IF NECESSARY, REPLACE THE ENGINE MAIN BEARING CAP BOLTS. VEHICLES INVOLVED ----------------- INVOLVED ARE SOME 1983 2000 MODELS EQUIPPED WITH 1.8L OVERHEAD CAM EFI 4-CYLINDER ENGINE (UPC CODE LH8) BUILT WITHIN THE FOLLOWING BREAK- POINTS: PLANT BEGINNING UP TO AND INCLUDING V.I.N. ------- ---------- ------------------- 1983 LORDSTOWN D7221900 D7227231

SOME VEHICLES WITH V.I.N.'S WITHIN THE ABOVE LISTED RANGE OF NUMBERS WERE CORRECTED AT THE ASSEMBLY PLANT AND WILL NOT APPEAR ON THE V.I.N. PRINTOUT. DEALER CAMPAIGN RESPONSIBILITY ------------------------------ DEALERS ARE TO INSPECT THE VEHICLE FOR SPECIFIC ENGINE SERIAL NUMBER AND IDENTIFICATION AND, IF NECESSARY, REPLACE THE ENGINE MAIN BEARING CAP BOLTS. DEALERS ARE TO SERVICE ALL VEHICLES SUBJECT TO THIS CAMPAIGN AT NO CHARGE TO OWNERS, REGARDLESS OF MILEAGE, AGE OF VEHICLE, OR OWNER- SHIP, 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. OWNER NOTIFICATION -------------------- OWNERS OF VEHICLES INVOLVED IN THIS CAMPAIGN WILL BE NOTIFIED BY PONTIAC MOTOR DIVISION ( TO READ COPY OF OWNER LETTER,REFER TO ACTUAL BULLETIN.) INVOLVED VEHICLES HAVE BEEN IDENTIFIED BY VEHICLE IDENTIFICATION NUMBER, OWNER NAME AND ADDRESS DATA, AND ARE FURNISHED TO THE IN- VOLVED DEALERS WITH THE CAMPAIGN BULLETIN. OWNER MANE AND ADDRESS DATA FURNISHED WILL ENABLE DEALERS TO FOLLOW UP WITH OWNERS IN- VOLVED IN THIS CAMPAIGN. THESE COMPUTER 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 IN SEVERAL STATES. ACCORDINGLY, YOU ARE URGED TO LIMIT THE USE OF THIS LISTING FOR THE FOLLOW-UP NECESSARY TO COMPLETE THIS CAMPAIGN. OWNERS OF VEHICLES RECENTLY SOLD FROM YOUR NEW VEHICLE INVENTORY ARE TO BE CONTACTED BY THE DEALER AND ARRANGEMENTS MADE TO MAKE THE REQUIRED MODIFICATION ACCORDING TO INSTRUCTIONS CONTAINED IN THIS BULLETIN. SERVICE PROCEDURE ----------------- 1. OPEN HOOD. 2. INSPECT ENGINE IDENTIFICATION PAPER TAG LOCATED ON ENGINE TIMING COVER. IF THE ENGINE IDENTIFICATION TAG IS MISSING, THE ENGINE IDENTIFICATION NUMBER IS ENGRAVED ON A HORIZONTAL BOSS LOCATED ON THE CYLINDER BLOCK, DIRECTLY UNDERNEATH THE #4 SPARK PLUG. 3. IF ENGINE SERIAL NUMBER IS BETWEEN 77117 AND 83420, PROCEED TO STEP 5. REPLACEMENT OF TEN (10) ENGINE MAIN BEARING CAP BOLTS IS NEEDED. 4. IF ENGINE SERIAL NUMBER IS NOT BETWEEN 77117 AND 83420, VEHICLE PASSES INSPECTION AND NO REPAIR IS NEEDED. PROCEED TO STEP 19. 5. HOIST VEHICLE. IF A TWIN POST IS BEING USED, POSITION JACKSTAND AT VEHICLE JACKING POINTS AND LOWER POST. 6. DRAIN OIL FROM CRANKCASE. 7. REMOVE EXHAUST PIPE FROM EXHAUST MANIFOLD. 8. IF EQUIPPED WITH AIR CONDITIONING, REMOVE LOWER AIR CONDITIONING STRUT BRACKET. 9. REMOVE FLYWHEEL DUST SHIELD. 10. REMOVE OIL PAN. SLIDE THE OIL PAN FORWARD, THEN DOWNWARD TO CLEAR THE OIL PUMP PICKUP TUBE. 11. INSPECT FOR BROKEN BOLTS AND THEN REPLACE THE TEN (10) MAIN BEAR- ING CAP BOLTS. TORQUE NEW MAIN BEARING CAP BOLTS TO 77 N.M (57 LB FT.) 11A. IF ANY BROKEN BOLTS ARE FOUND IN THE #1, #2, #3 0R #4 MAIN BEAR- ING POSITIONS, REMOVE THE MAIN BEARING CAP AND INSPECT THE BEAR- ING. 11B. IF ANY MAIN BEARINGS APPEAR TO BE DAMAGED OR HAVE SPUN, REPLACE THE BEARING. 11C. IF A BROKEN BOLT IS FOUND IN THE #5 MAIN BEARING POSITION, VISUALLY INSPECT THE CAP TO DETERMINE WHETHER THE BEARING HAS MOVED. IF THE BEARING HAS NOT MOVED, REPLACE THE BEARING CAP BOLTS ONLY. 11D. IF REMOVAL OF #5 MAIN BEARING CAP IS NECESSARY, THE AREA REQUIR- ING SEALER MUST BE CLEANED AND RESEALED USING DEALER KIT GM # 3997597 REFER TO ILLUSTRATION THE 1983 FRONT WHEEL DRIVE SERVICE MANUAL, SECTION 6A2, FIGURE 6A2-38. BE SURE THE REAR MAIN OIL SEAL IS PROPERLY ALIGNED. 11E. IF THE ENGINE BLOCK HAS BEEN DAMAGED AS A RESULT OF A SPUN BEAR- ING, REPLACE THE ENGINE BLOCK. 12. INSTALL OIL PAN AND NEW OIL PAN GASKET. APPLY RTV SEALER TO OIL PAN GASKET AT THE OIL PUMP MATING SURFACE. 13. IF EQUIPPED WITH AIR CONDITIONING, INSTALL AIR CONDITIONING STRUT BRACKET. 14. INSTALL FLYWHEEL DUST SHIELD. 15. INSTALL EXHAUST PIPE TO EXHAUST MANIFOLD. 16. LOWER VEHICLE. 17. REFILL CRANKCASE WITH OIL. 18. START ENGINE AND CHECK FOR OIL LEAKS. 19. EACH VEHICLE MODIFIED IN ACCORDANCE WITH THE INSTRUCTIONS OUT- LINED IN THIS SERVICE PROCEDURE WILL REQUIRE A CAMPAIGN IDENTI- FICATION LABEL. EACH LABEL PROVIDES A SPACE TO INCLUDE THE CAMPAIGN NUMBER, THE FIVE-DIGIT DEALER CODE OF THE DEALER PER- FORMING THE CAMPAIGN SERVICE, AND THE DATE VEHICLE WAS CAMPAIGNED. THIS INFORMATION MAY BE INSERTED WITH A TYPEWRITER OR BALLPOINT PEN. INSTALL THE LABEL ON THE FAN SHROUD WHERE IT IS READILY VISIBLE. PARTS INFORMATION ----------------- CAMPAIGN REQUIREMENTS OF PART NUMBER 11072446 (BEARING BOLTS -TEN (10) PER VEHICLE) ARE TO BE OBTAINED BY THE DEALER FROM WDDGM. THE REMOVED PARTS ARE TO BE RETAINED FOR DISPOSITION BY ZONE PERSONNEL VERY FEW VEHICLES WILL NEED REPLACEMENT OF ENGINE MAIN BEARING CAP BOLTS. ENCLOSED WITH THE COPY OF THIS BULLETIN --------------------------------------- A LIST OF THOSE VEHICLES INVOLVED, WHICH OUR RECORDS INDICATE ARE IN YOUR GEOGRAPHICAL AREA, IS ATTACHED. ADVISE THE ZONE IF VEHICLES APPEARING ON THE ATTACHED LIST ARE NOT IN YOUR AREA. (IF LIST OF VEHICLES IS NOT ATTACHED, OUR RECORDS INDICATE NO AFFECTED VEHICLE(S) IN YOUR AREA.) IF A VEHICLE HAS BEEN TRANSFERED OR SOLD TO ANOTHER LOCATION, PLEASE FORWARD ANY NEW NAME AND ADDRESS OF THE VEHICLE TO YOUR PONTIAC ZONE OFFICE. RECORDING COMPLETION --------------------- 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. DEALERS SHOULD STILL SUBMIT WARRANTY CLAIMS FOR CREDIT IN THEIR NORMAL MANNER WHEN THEY PERFORM THE SERVICE AS FOLLOWS: A COMPLETED WARRANTY CLAIM IS TO BE KEPT AS A PERMANENT RECORD OF COMPLETION. WARRANTY CREDIT --------------- A SEPARATE REPAIR ORDER MUST BE USED FOR EACH VIN. DESCRIPTION LABOR LABOR OTHER PARTS OPERATION TIME LABOR ALLOWANCE HOURS ------------- ----------- ----- ------ ---------- INSPECT ENGINE V1580 0.2 01. - NUMBER, NO FURTHER ACTION REQUIRED. INSPECT ENGINE NUMBER AND REPLACE TEN(10) ENGINE BOLTS - WITH A/C V1581 1.6 0.1 $10.54 - WITHOUT A/C V1582 1.4 0.1 $10.54 INSPECT ENGINE NUMBER AND REPLACE TEN(10) ENGINE BOLTS AND ONE(1) MAIN BEARING - WITH A/C V1583 1.8 0.1 $10.54 - WITHOUT A/C V1584 1.6 0.1 $10.54

ADD 0.2 HR. FOR EACH ADDITIONAL MAIN BEARING REPLACEMENT IN ADDITION, DEALERSHIP WILL RECEIVE 0.1 HOURS CREDIT FOR DEALER ADMINISTRATIVE 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 RECEIVE ZONE AUTHORIZATION. PARTS CREDIT IS FOR DEALER PRICE OF OIL PAN GASKET, PART NUMBER 90106425, ($3.61) PLUS 30% ($1.08), AND THREE QUARTS OF ENGINE OIL ($4.50) PLUS 30% ($1.35). MAIN BEARING CAP BOLTS AND MAIN BEARINGS ARE TO BE LISTED ON THE WAR- RANTY CLAIM IN THE NORMAL MANNER THESE PARTS WILL BE CREDITED AT DEALER NET PRICE PLUS 30% DEALER HANDLING ALLOWANCE. FAILURE CODE 96 MUST BE USED WITH THE LABOR OPERATION. CREDITING ---------- DEALERS WILL BE CREDITED VIA WARRANTY DOCUMENT OR TERMINAL TRANSMISSION WHICHEVER IS THEIR NORMAL METHOD OF SUBMISSION OF PAYMENT. CLAIMS MUST CONTAIN ALL INFORMATION REQUIRED AND SHOULD LIST THE LABOR OPERATION AS OUTLINED. REPAIRS SUBMITTED FOR VEHICLES NOT INVOLVED IN THE CAMPAIGN WILL NOT BE PAID.

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.