SPECIAL POLICY ADJUSTMENT 3.1L ENGINE PISTON PLATE WEAR
SUBJECT: SPECIAL POLICY ADJUSTMENT 3.1L ENGINE PISTON PLATING WEAR
MODELS/YEARS: 1990 TRANS SPORT EQUIPPED WITH 3.1L (VIN CODE D)
CONDITION
General Motors has determined that some 1990 Pontiac Trans Sport model vehicles built with 3.1L LG6 engines (VIN Code D), may develop a condition of premature wear of the pistons due to low adhesion of the tin plating. Evidence of this condition would be a cold engine knocking noise at low ambient temperatures. This condition will not lead to engine failure and is typically limited to cylinders #2, #4, and #6.
VEHICLES INVOLVED
Involved are 1990 Pontiac Trans Sport model vehicles built with 3.1L LG6 engines (VIN Code D), within the following breakpoints:
Up To And Year Model Beginning Including ---- ----- --------- --------- 1990 Trans Sport LT200001 LT500051
SPECIAL POLICY ADJUSTMENT
This special policy covers the condition described above on vehicles in specific cold climate states for a period of six (6) years or 72,000 miles, whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. If piston replacement is required due to this condition, an engine replacement should be made at no charge to the owner rather than replacement of individual pistons. This special policy adjustment applies ONLY to the repair required as a RESULT of the described condition; it does not cover other conditions which may necessitate a partial engine replacement.
OWNER NOTIFICATION
Owners in specific cold climate states will be notified of this special policy on their vehicle by Pontiac Division (see copy of the owner letter included with this bulletin).
STATES INVOLVED IN OWNER NOTIFICATION
The following is the list of states defined as "cold climate states."
Alaska (AK) Iowa (IA) New Hampshire (NH)Utah (UT) Colorado (CO) Maine (ME) New Jersey (NJ) Vermont (VT) Connecticut (CT) Maryland (MD) New York (NY) Virginia (VA) Delaware (DE) Massachusetts (MA)North Dakota (ND) West Virginia (WV) Dist. of Columbia (DC)Michigan (MI) Ohio (OH) Wisconsin (WI) Idaho (ID) Minnesota (MN) Pennsylvania (PA) Wyoming (WY) Illinois (IL) Montana (MT) Rhode Island (RI) Indiana (IN) Nebraska (NE) South Dakota (SD)
OWNER REIMBURSEMENT
Customer claims for reimbursement on previously paid repairs to replace pistons (or partial engine) as a result of premature piston wear due to low adhesion of tin plating, are to be submitted by August 31, 1994 (this time limitation may be longer depending upon the law in some states, such as Virginia, Connecticut, and Wisconsin). Repairs must have occurred within six years of the date the vehicle was originally placed in service, or 72,000 miles, whichever occurs first.
Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expense, a description of the repair, the date of the repair, and the person or entity who performed the repair. Customers' claims for reimbursement are to be submitted using 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 must be forwarded to and processed by the Zone Office. Customers from the states of Virginia, Connecticut and Wisconsin must submit request for reimbursement directly to Pontiac per the owner letter.
SERVICE PROCEDURE
(Note all radio settings, clock, etc.)
1. Disconnect battery cables.
2. Remove air cleaner assembly.
3. Drain cooling system.
4. Discharge/recover A/C system refrigerant. Refer to service manual for discharging A/C system, section 1B.
5. Disconnect ECM harness at ECM and push through to engine compartment.
6. Remove necessary ECM harness fasteners to chassis and lay harness on engine assembly.
7. Remove throttle and T.V. cable at TBI unit.
8. Disconnect fuel lines at TBI unit.
9. Remove transaxle shift linkage and bracket at transaxle.
10. Remove radiator and heater hoses at engine side.
11. Remove L.H. engine compartment crossbrace with washer reservoir assembly.
12. Remove engine wiring harness from block connector at left hood hinge and lay on engine assembly.
13. Remove engine torque strut to engine.
14. Raise vehicle.
15. Remove transaxle cooler lines at radiator.
16. Remove front L.H. and R.H. wheel locks, if equipped.
17. Remove front L.H. and R.H. tire and wheel assemblies.
18. Remove L.H. and R.H. tie rod ends to knuckle.
19. Remove L.H. and R.H. control arm ball joints from steering knuckles. Refer to service manual for details of removal procedure, section 3C.
20. Remove L.H. and R.H. axle shaft from transaxle. Refer to service manual for details of removal procedure, section 4D.
21. Position axle/hub assembly up and wire to strut.
22. Remove intermediate steering shaft pinch bolt and shaft from steering gear.
23. Remove A/C compressor suction/discharge fitting at rear of compressor and cover to prevent damage/contamination.
24. Remove all starter wiring at starter assembly and engine ground.
25. Remove starter assembly and A/C compressor brace from engine.
26. Remove transaxle converter shields.
27. Remove flywheel to converter attaching bolts.
28. Remove exhaust pipe to exhaust manifold bolts and springs.
29. Remove R.H. inner fender shield and power steering hose retaining clamps at R.H. frame rail.
30. Remove engine ground strap from lower tie bar. Refer to service manual, figure 9 section 6D5.
31. Remove engine mount to frame retaining bolts and washers.
32. Lower vehicle and support engine/transaxle for removal from vehicle onto stand J36295.
33. Remove engine/transaxle frame to body retaining bolts and raise vehicle.
34. Remove serpentine belt guide cover and belt.
35. Remove generator wiring, generator and support bracket.
36. Remove power steering pump and lines from engine. Wire pump assembly and line to frame.
37. Remove A/C compressor support brace and compressor assembly.
38. Remove front and rear coolant by-pass pipes from engine.
39. Remove water pump from front cover.
40. Remove spark plug wiring at plugs and wire routing retainers.
41. Remove TBI wiring, hoses and TBI unit from intake manifold.
42. Remove engine wiring harness from engine.
43. Remove distributor retainer and distributor assembly from engine.
44. Remove both rocker arm covers.
45. Remove intake manifold assembly.
46. Remove serpentine belt tensioner from engine front cover.
47. Remove torque strut and A/C compressor mounting bracket.
48. Remove torsional dampener bolt from crankshaft.
49. Remove torsional dampener from crankshaft using J24420-B.
50. Remove exhaust crossover pipe from R.H. and L.H. exhaust manifolds.
51. Remove R.H. and L.H. engine exhaust manifolds.
52. Remove ignition coil and bracket.
53. Remove Electronic Vacuum Regulator Valve (EVRV) and bracket.
54. Remove oil filter adaptor and sensor assembly.
55. Remove Electronic Spark Control (ESC) knock sensor.
56. Remove engine coolant sensor from cylinder head.
57. Remove engine to transaxle bracket bolts and bracket.
58. Remove engine block heater, if equipped.
59. Remove engine to transaxle retaining bolts.
60. Separate engine from transaxle.
61. Remove engine mount bracket bolts at engine block.
62. Remove flywheel from engine.
63. Clean all gasket surfaces on new engine (P/N 12513152).
64. Install flywheel to new engine, apply GM thread locker to all flywheel bolts and tighten bolts to 70 N.m (52 lb. ft.).
65. Install engine to front mount bracket. Tighten three front bolts to 80 N.m (59 lb.ft.) and one side bolt to 110 N. m (80 lb. ft.).
66. Install engine to transaxle retaining bolts. Tighten bolts to 75 N.m (55 lb.ft.).
67. Install engine to transaxle bracket. Refer to service manual for details of installation procedure, section 6A.
68. Install new engine oil level indicator (dipstick) tube on new engine (tube packaged loose with Goodwrench engine).
69. Install new engine oil level indicator (dipstick) into indicator tube (indicator packaged loose with Goodwrench engine).
70. Install engine block heater, if equipped.
71. Install engine coolant sensor.
72. Install ESC knock sensor. Tighten sensor to 19 N.m (14 lb.ft.). Note: Be sure threads are clean.
73. Install oil filter adaptor, including oil pressure sensor and new adaptor gasket (P/N 12337894). Tighten connector through adaptor to 39 N.m (29 lb.ft.).
74. Install EVRV and bracket to cylinder head.
75. Install ignition coil and bracket to cylinder head.
76. Install R.H. exhaust manifold. Refer to service manual for details of installation procedure, section 6A4.
77. Install L.H. exhaust manifold. Refer to service manual for details of installation procedure, section 6A4.
78. Install exhaust crossover pipe. Tighten nuts to 25 N.m (18 lb.ft.).
79. Install torque strut/A/C compressor mounting bracket at engine.
80. Install torsional damper to crankshaft. Refer to service manual for section 6A4.
81. Install serpentine belt tensioner assembly to front cover. Refer to service manual for details of installation procedure, section 6A4.
82. Install intake manifold assembly. Refer to service manual for details of installation procedure, section 6A4.
83. Install both rocker arm covers. Use the rocker cover gaskets that came with Goodwrench engine. Refer to service manual for details of installation procedure, section 6A4.
84. Install distributor assembly and new seal 0-ring P/N 1977935. Refer to service manual for details of installation procedure, section 6D4. Note: Do not tighten retaining bolt at this time.
85. Install TBI unit and new gasket (P/N 14092220). Refer to service manual for details of installation procedure, section 6E2.
86. Install engine wiring harness and vacuum harness on engine.
87. Install spark plugs and spark plug wires.
88. Install water pump and new gasket (P/N 10182374). Tighten bolts to 10 N.m (89 lb.in.).
89. Install front and rear coolant by-pass pipes.
90. Install A/C compressor assembly and brace. Refer to service manual for details of installation procedure, section 1B.
91. Install power steering pump and lines. Refer to service manual for details of installation procedure, section 3B1.
92. Install generator assembly, brace and wiring.
93. Install serpentine drive belt and cover.
94. Install engine/transaxle to vehicle.
95. Install power steering line retaining clamps and R.H. inner fender shield.
96. Install exhaust pipe to exhaust manifold bolts and springs and new exhaust manifold pipe seal P/N 10094825. Refer to service manual for details of installation procedure, section 6F.
97. Install flywheel to converter attachment bolts. Tighten bolts to 60 N.m (44 lb.ft.).
98. Install converter cover.
99. Install starter assembly, including all wiring and A/C compressor brace.
100. Install A/C compressor suction/discharge fitting at compressor.
101. Install intermediate steering shaft to gear and pinch bolt.
102. Install R.H. and L.H. axle assemblies to transaxle.
103. Install L.H. and R.H. steering knuckle to ball joint pinch bolt.
104. Install L.H. and R.H. tie rod ends to steering knuckle.
105. Install L.H. and R.H. tire and wheel assemblies and wheel locks, if equipped.
106. Install ground strap at lower tie bar from engine harness.
107. Install transaxle cooler lines at radiator.
108. Lower vehicle.
109. Install engine torque strut to engine.
110. Install engine wiring harness to block connector at left hood hinge.
111. Install L.H. engine compartment crossbrace with washer reservoir.
112. Install radiator and heater hoses to engine.
113. Install transaxle shift bracket and linkage to transaxle.
114. Install throttle and T.V. cables at TBI unit.
115. Install fuel lines at TBI unit.
116. Install necessary ECM harness fasteners to chassis.
117. Install ECM harness through cowl and connect at ECM.
118. Refill coolant system with new coolant. Add two (2) engine cooling system sealer pellets from package, P/N 3634621, to the radiator.. Coolant must be mixed with equal mount of water to provide proper protection.
119. Install engine oil.
120. Install air cleaner assembly.
121. Attach battery cables.
122. Check engine timing and tighten distributor retainer.
123. Check and adjust toe.
124. Recharge A/C system. Refer to service manual for recharging procedure, section 1B.
125. Start engine and verify no fluid leaks.
126. Reset radio, clock.
PARTS INFORMATION
To ensure parts are obtained as soon as possible, order them from General Motors Service Parts Operations (GMSPO) on a C.I.O. order, with NO special instruction code, but order on an advise code (2).
Part Quantity Description Number Per Vehicle ----------- ------ ------------ Goodwrench Engine 12513152 1 Intake Manifold Gasket Kit 12520756 1 Throttle Body Gasket 14092220 1 Distributor O-Ring 1977935 1 Water Pump Gasket 10182374 1 Oil Filter Adaptor Gasket 12337894 1 Seal, Exhaust Manifold Pipe 10094825 1 Coolant, Engine (bulk) 1052753 6.7 qts. Engine Oil, 5W-30 (w/Filter) 12345612 4.5 qts. Oil Filter (PF51) 25010908 1 Engine Coolant System Sealer (Pkg. of 6) 3634621 2 pellets
WARRANTY 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 Labor Labor Labor Repair Performed FC Operation Hours Hours ---------------- --- --------- ----- ----- Goodwrench Engine Replace 95 T3322 8.2 ---
Add Times:
W/Locking Wheel Covers/Nuts 0.1 W/Air Conditioning 0.9 Clean Parts On Vehicles Over 30,000 Miles if Necessary 0.5 W/Block Heater 0.1
Customer Reimbursement 95 T3324 --- 0.2*
* 0.2 hour for clerical administration may be applied for in the Other Labor Hours on customer reimbursement claims totaling $300.00 or less.
Parts Allowance: Current dealer price, plus 30% handling allowance.
Dear Pontiac Owner:
As the owner of a 1990 Pontiac Trans Sport equipped with a 3. 1 L engine, your continued satisfaction with our products 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 1990 Pontiac Trans Sport model vehicles built with 3.1L engines may develop a condition of premature wear of the pistons that results in a cold engine knocking noise at low ambient temperatures. This condition will not lead to engine failure.
ACTION:
------ In addition to your normal warranty coverage, GM is providing special coverage if your vehicle is affected by the described condition. If the above mentioned condition occurs within six (6) years of the date your vehicle was originally placed in service, or 72,000 miles, whichever occurs first, your vehicle will be repaired free of charge. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you desire an estimate of the total time required to schedule, process and return your vehicle.
Please note that this action is NOT a recall; you do not need to call or visit your Pontiac dealer unless the above described condition has occurred on your vehicle.
REIMBURSEMENT:
------------- (Statement for all states except as shown below.)
If you have already paid for some or all of the cost to have a head gasket replaced and your mileage and in-service time was less than 72,000 miles/6 years, you should contact your Pontiac Dealer Service Department to seek reimbursement. Please provide your dealer with your original paid receipts or invoices verifying the repair, the amount charged, proof of your payment and date of payment of those charges by August 31, 1994.
(Statement for Virginia, Connecticut and Wisconsin)
If you have already paid for some or all of the cost to have a head gasket replaced and your mileage and in- service time was less than 60,000 miles/6 years, you should write to Pontiac Division, One Pontiac Plaza, Room 317B, Pontiac, MI 48340 to seek reimbursement. Please provide your original paid receipts or invoices verifying the repair, the amount charged, proof of your payment and 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.
We suggest you keep this letter and place it in the instrument panel compartment of your vehicle with the Owner's Manual, Maintenance Schedule, and Warranty Booklet. This letter identifies your vehicle. Presentation of this letter to your dealer will assist in making the necessary (inspection/correction) in the shortest possible time.
We regret any inconvenience that you may experience; however, we have taken this action in the interest of your continued satisfaction with our products.
PONTIAC DIVISION GENERAL MOTORS CORPORATION
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.
