Engine Exchange Program for 2.2L ECOTEC Engine (VIN F - RPO L61)

This bulletin will cover the 2.2 L ECOTEC (VIN F -- RPO L61) Engine Exchange Program only for the 2002 models listed above. This Engine Exchange Program will be in effect for Chevrolet Cavalier and Pontiac Sunfire until April 10, 2002.

Product teams continually seek valuable information for product engineering improvements. An engine exchange program will be administered by GM Powertrain during the 2002 model year. The duration of the program is six months for the above applications. Guidelines for honoring engine exchange requests under the engine exchange program are being strictly enforced for the 2002 model year.

You must call the Technical Assistance Center (TAC) to request an exchange. TAC may request the dealer to perform additional work. In addition to information from the vehicle Repair Order, TAC will need the Dealer Franchise Code, and the name and number of the person to contact at the dealership for follow-up on the engine exchange, usually the Service Manager or Parts Manager. TAC will also need to know whether the vehicle has a 4-speed automatic or 5-speed manual transaxle. Please also provide the Engine Broadcast Code, located on a sticker on the top front of the camshaft cover, or ink-stamped on a flat on the oil filter bowl on the front of the block (Example: RAD 105170620).

If any internal components of a 2002 model year engine require replacement, the engine must be exchanged. There are certain repairs that can be performed on the 2.2 L ECOTEC (L61) engine that do not require an engine to be exchanged. During the six-month Engine Exchange program period, dealers may replace any of the components listed below without participating in the Engine Exchange program:

Oil leaks, coming from any of the components on the above list, should be repaired at the dealership without exchanging the engine. Oil leaks coming from the oil pan or front cover assembly will be reviewed on a case-by-case basis. Verify that the leak is originating from the front cover or oil pan by performing an oil dye check. Once the leak is verified, contact the Technical Assistance Center to determine if an engine exchange is necessary. If the engine has a leak that is NOT coming from the oil pan, front cover, or a component on the above list, the engine must be exchanged.

Engine components on the Serviceable Component list above must be serviced according to the repair procedures in the applicable Service Information publication (manual). Engine components NOT included in the above list will require an engine exchange.

Important: Engine repairs or failures that are caused by components external to the engine will NOT fall under the engine exchange program. For example, engine coolant lines incorrectly installed, causing an engine failure, will have to go through GMSPO to obtain an engine assembly. The exchange program was created as a way to correct internal concerns and to take what is learned and find a way to eliminate these concerns. External components causing failures do not provide any useful information in improving an engine. The engine received from GMSPO will be a new service engine.

A thorough diagnosis must be performed on the condition in order to prevent unnecessary component replacements. Contact Technical Assistance, phone numbers listed above, to verify the proper diagnosis has been performed. Upon review of the diagnosis, Technical Assistance will establish a case reference number and make arrangements for shipping an exchange unit to your dealership. To increase the effectiveness of the program, the Warranty Parts Center (WPC) will request the return by faxing a WPC Special Request to the dealership within 24 hours of the call to Technical Assistance. The dealer is strongly encouraged to return the defective engine to the WPC as soon as repairs are completed. DO NOT SHIP AN ENGINE TO THE WPC WITHOUT AN OFFICIAL WPC REQUEST.

Important: Failure to return the concerned engine will result in the dealership being debited in the amount of an entire engine assembly (dealer net).

The removed unit must be returned complete in the original exchange shipping container. For effective engineering analysis, please DO NOT remove any components. Dress items on the removed unit must remain the same as the replacement engine (e.g., exhaust manifolds, throttle body, etc.). Dealerships returning engines/components having been partially disassembled will be judged as violating this procedure and, as such, will be billed for all materials furnished.

Notice: The exchange unit will be shipped with a quantity of oil; check oil level before starting the engine. Low oil level could result in internal engine damage.

Included with the exchange unit will be return shipping instructions, including a return shipping label (freight collect at destination) and partially completed Bill of Lading.

A request for return of engine or component will be faxed to the dealership within 24 hours of the dealer call to Technical Assistance.

Shipping Preparation

1. Remove the engine assembly/component as outlined in the applicable Service Manual. Drain all fluids from the removed engine.
2. Retorque any fasteners that were loosened or removed to the original torque specification.
3. Remove any plastic shipping plugs and covers from the exchange unit and install them on the removed unit.
4. If the concerned engine leaks, mark the area directly on the engine with a permanent marker.
5. Write the TAS case reference number on the repair order form.
6. Write the TAS case reference number on the component in a visible location.
7. Place the removed engine into the original shipping container. Attach completed return shipping tag to engine.

Shipping Instructions

1. Place a copy of the repair order, a copy of the WPC Special Request, the completed return checklist and product feedback forms into the plastic press-on envelope.
2. Remove the original shipping label and attach the plastic press-on envelope with the return shipping label on it to the container. The Bill of Lading and Custom Papers (for Cross-Border Shipments) provided with the exchange engine are the only other documents required to be inserted into the clear envelope to return the removed engine.
3. Write the WPC request number and the TAS case reference number on the outside of the container with a permanent marker. To simplify the Exchange Program's core return process, the WPC will be coordinating all activities for core returns. See Service Bulletin 99-00-89-019A (Dealers in Canada should refer to Home Office Letter 1999-201) for detailed shipping information.
4. Contact Yellow Freight at 800-610-6500 (option 1) to arrange for pickup.

For vehicles repaired under warranty, use:

Use Part Number 90537868 for vehicles equipped with a 5-speed manual transaxle.

Use Part Number 90537869 for vehicles equipped with a 4-speed automatic transaxle.

Important: Applicable miscellaneous items such as engine oil and coolant should be added to the part allowance amount and claimed in the Parts Cost column and not included in the Net Amount (DMN) column of the warranty claim.

Your cooperation is greatly appreciated. Prompt return of the original engine will increase the effectiveness of this program. If you have any questions regarding the exchange program administrative procedures, please contact Technical Assistance.