For 1990-2009 cars

# ENGINE EXCHANGE PROGRAM

REVISION: 07/29/94

THIS BULLETIN IS BEING REVISED TO ADD C AND H CARS. PLEASE DISCARD BULLETIN 476108 (GROUP REFERENCE 6 - ENGINE). ----------------------------------------------------------------------

#### SUBJECT: ENGINE EXCHANGE PROGRAM FOR 3800 SERIES II V6 ENGINE

#### MODELS: 1995 BUICK PARK AVENUE AND RIVIERA 1995 OLDSMOBILE 88 ROYALE AND 98 REGENCY 1995 PONTIAC BONNEVILLE WITH 3800 SERIES II V6 ENGINE (VIN K - RPO L36)

TO OBTAIN PRODUCT FEEDBACK ON THE NEW 3800 SERIES II V6 ENGINE, AN EXCHANGE PROGRAM HAS BEEN APPROVED. TO PARTICIPATE IN THIS PROGRAM, FOLLOW THE GUIDELINES IN THIS BULLETIN. THIS PROGRAM IS IN EFFECT THROUGH SEPTEMBER 1, 1995.

THIS EXCHANGE PROGRAM WILL BE ADMINISTERED BY DIVISIONAL TECHNICAL ASSISTANCE.

THE FOLLOWING EXPLAINS THE REQUIREMENTS REGARDING NON-SERVICEABLE AND SERVICEABLE ITEMS, EXCHANGE PROCEDURE, SHIPPING INSTRUCTIONS AND WARRANTY CLAIMS PROCESSING PROCEDURES.

***THE FOLLOWING COMPONENTS ARE NOT TO BE REMOVED FOR SERVICE:***

CYLINDER BLOCK OIL PUMP GEARS CYLINDER HEAD GASKETS REAR MAIN SEAL/CARRIER PLATE CYLINDER HEADS CAMSHAFT AND DRIVE PISTON ASSEMBLY (PISTONS, RODS, DRIVE BELT TENSIONER BRACKET RINGS) BALANCE SHAFT AND DRIVE OIL PAN AND WINDAGE TRAY OIL FILTER ADAPTER ROD AND MAIN BEARINGS UPPER AND LOWER INTAKE MANIFOLDS CRANKSHAFT VALVE TRAIN COMPONENTS TIMING CHAIN COVER

A. ENGINE COMPONENTS WHICH MAY BE SERVICED (WITHOUT EXCHANGE):

#### NOTE: ANY DEFICIENT ENGINE COMPONENT ON THE FOLLOWING LIST SHOULD BE REPAIRED ACCORDING TO SERVICE PROCEDURES IN THE APPLICABLE VEHICLE SERVICE MANUAL.

1. BRACKETS: ENGINE LIFT BRACKETS, AND ACCELERATOR CABLE BRACKET 2. WATER PUMP: WATER PUMP AND RELATED GASKETS, WATER OUTLET, THERMOSTAT, HEATER PIPES AND "O" RINGS 3. VACUUM TUBES: VACUUM CONNECTORS AND HOSES 4. IGNITION: SPARK PLUGS, LEFT AND RIGHT HAND SECONDARY WIRES, AND IGNITION COIL PACK 5. ELECTRICAL COMPONENTS: ALL SENSORS INCLUDING KNOCK SENSORS, COOLANT LEVEL SENSOR, COOLANT TEMPERATURE SENSOR, CRANK TIMING SENSOR, CAM TIMING SENSOR, OXYGEN SENSORS, TPS SENSOR, IAC VALVE, AND AIR TEMPERATURE SENSOR 6. VALVE COVERS AND GASKETS 7. EXHAUST MANIFOLDS AND CROSS-OVER PIPE 8. HARMONIC BALANCER 9. EGR SYSTEM: EGR VALVE, EGR TUBES, AND EGR ADAPTER 10. FUEL SYSTEM: FUEL LINES, FUEL PRESSURE REGULATOR, FUEL RAIL, AND FUEL INJECTORS 11. THROTTLE BODY AND RELATED COMPONENTS 12. INJECTOR WIRING HARNESS 13. BLOCK HEATER (IF APPLICABLE) 14. FLYWHEEL ASSEMBLY 15. OIL DIPSTICK AND TUBE, OIL FILL CAP, OIL FILTER AND OIL COOLER 16. COMPLETE ACCESSORY DRIVE AND SUPPORTING BRACKETS: INCLUDING GENERATOR, A/C COMPRESSOR, POWER STEERING PUMP, AND ALL ATTACHING PARTS (EXCEPT DRIVE BELT TENSIONER BRACKET) 17. STARTER MOTOR

B. EXCHANGE PROCEDURE: CONTACT TECHNICAL ASSISTANCE TO ESTABLISH A CASE REFERENCE NUMBER AND TO MAKE ARRANGEMENTS FOR SHIPPING AN EXCHANGE UNIT TO YOUR DEALERSHIP.

TO INCREASE THE EFFECTIVENESS OF THE PROGRAM, THE UNIT REMOVED FROM THE VEHICLE MUST BE RETURNED IMMEDIATELY ***(NOT LATER THAN 10 DAYS AFTER DATE OF RECEIPT OF THE REPLACEMENT UNIT).***

***FAILURE TO RETURN THE CONCERNED ENGINE WILL RESULT IN THE DEALERSHIP BEING BILLED THE VALUE OF AN EXCHANGE ENGINE***

THE REMOVED UNIT MUST BE RETURNED COMPLETE IN THE SHIPPING CONTAINER PROVIDED. TO INCREASE THE EFFECTIVENESS FOR ENGINEERING ANALYSIS, PLEASE DO NOT REMOVE ANY COMPONENTS. ENGINE DRESS ON THE REMOVED UNIT MUST REMAIN THE SAME AS THE REPLACEMENT ENGINE (I.E., EXHAUST MANIFOLDS, THROTTLE BODY, ETC.). DEALERSHIPS RETURNING UNITS HAVING BEEN EVEN PARTIALLY DISASSEMBLED WILL BE JUDGED AS VIOLATING THIS PROCEDURE AND, AS SUCH, WILL BE SUBJECT TO BEING BILLED FOR ALL MATERIALS FURNISHED.

THE ENGINE PLANT WILL FURNISH AND DELIVER THE EXCHANGE ENGINE TO THE DEALER FREE OF CHARGE.

#### NOTE: AN EXCHANGE ENGINE WILL BE SHIPPED WITHIN TWENTY-FOUR (24) HOURS OR ONE (1) WORKING DAY. UNLESS NOTIFIED OTHERWISE, THE EXCHANGE ENGINE WILL BE SHIPPED VIA GROUND TRANSPORTATION.

C. DEALER SHIPPING INSTRUCTIONS DRAIN ALL FLUIDS FROM THE CONCERNED ENGINE AND ***REPLACE PLUGS.***

REMOVE THE CONCERNED ENGINE FROM THE VEHICLE AS OUTLINED IN THE SERVICE MANUAL.

REMOVE ALL OF THE PLASTIC SHIPPING PLUGS AND COVERS FROM THE EXCHANGE ENGINE AND INSTALL THEM ON THE REMOVED ENGINE.

RECRATE THE REMOVED ENGINE INTO THE ORIGINAL SHIPPING CONTAINER.

PLACE A COPY OF THE REPAIR ORDER IN THE ORIGINAL ENVELOPE AND ATTACH THE ENVELOPE TO THE RETURNED ENGINE.

THE EXCHANGE UNIT WILL HAVE AN ENVELOPE ATTACHED TO IT CONTAINING THE RETURN SHIPPING LABEL.

PLACE THE SHIPPING LABEL OVER THE ORIGINAL SHIPPING LABEL ON THE SHIPPING CONTAINER.

THE BILL OF LADING AND CUSTOM PAPERS PROVIDED WITH THE EXCHANGE ENGINE ARE THE ONLY DOCUMENTS REQUIRED TO RETURN THE REMOVED ENGINE.

#### NOTE: THE RETURN CARRIER TO BE USED IS DETERMINED BY THE DEALER GEOGRAPHIC LOCATION. REFER TO THE PINK SHEET CONTAINED IN THE ENVELOPE ATTACHED TO THE EXCHANGE ENGINE FOR MORE DETAILS.

AFTER THE BILL OF LADING HAS BEEN DATED AND SIGNED BY THE CARRIER, RETAIN THE LAST COPY WITH YOUR REPAIR ORDER. GIVE THE OTHER TWO COPIES TO THE CARRIER. YOUR SIGNED COPY OF THE BILL OF LADING IS YOUR PROOF OF RETURNING THE ENGINE.

THE RETURNED ENGINE IS TO BE SHIPPED FREIGHT COLLECT, AS DIRECTED IN THE SHIPPING PAPERS PROVIDED WITH THE NEW ENGINE.

IF THE ENVELOPE CONTAINING SHIPPING INFORMATION BECOMES LOST, PLEASE CONTACT "MATERIAL CONTROL" AT THE FLINT V6 MANUFACTURING SITE ON PHONE NUMBER (810) 236-6696 FOR SHIPPING INSTRUCTIONS.

FAILURE TO RETURN THE REMOVED ENGINE WILL RESULT IN THE DEALERSHIP BEING BILLED $2,587.50 FOR THE NEW ENGINE FURNISHED, PLUS AN ADMINISTRATIVE CHARGE.

D. WARRANTY CLAIMS PROCESSING PROCEDURE UPON COMPLETION OF REPLACING THE ENGINE, A WARRANTY CLAIM IS TO BE SUBMITTED TO THE MARKETING DIVISION.

LABOR OPERATION *PART NUMBER DESCRIPTION ALLOWANCE --------- ----------- --------- J1880 REPLACE ENGINE ASSEMBLY $426.20

USE PUBLISHED LABOR TIMES.

*THE AMOUNT IDENTIFIED IN THE "PART ALLOWANCE" COLUMN ABOVE REPRESENTS 40 PERCENT OF THE DIFFERENCE BETWEEN THE CURRENT GMSPO DEALER NET PRICE AND THE ENGINE RETURN CREDIT (CORE ALLOWANCE). THIS AMOUNT IS TO BE PLACED IN THE NET AMOUNT COLUMN OF THE CLAIM.

***NOTE: APPLICABLE MISCELLANEOUS ITEMS SUCH AS ENGINE OIL, AND ENGINE COOLANT SHOULD BE ADDED TO THE ABOVE PART ALLOWANCE AMOUNT AND INCLUDED IN THE NET AMOUNT (DMN) COLUMN OF THE CLAIM.***

YOUR COOPERATION IS GREATLY APPRECIATED. PROMPT RETURN OF YOUR CONCERNED UNIT WILL INCREASE THE EFFECTIVENESS OF THIS PROGRAM. IF YOU HAVE ANY QUESTIONS REGARDING THE EXCHANGE PROGRAM ADMINISTRATIVE PROCEDURES, PLEASE CONTACT DIVISIONAL TECHNICAL ASSISTANCE (MISCELLANEOUS GROUP/ENGINE MECHANICAL).

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GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS ONLY. BULLETINS ARE WRITTEN TO INFORM THOSE TECH- NICIANS OF A CONDITION POSSIBLY OCCURRING ON A VEHICLE, OR TO PROVIDE INFORMATION ASSISTING IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS, AND TRAINING TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THE BULLETIN APPLIES TO ALL VEHICLES. SEE AN AUTHORIZED GM DEALER FOR INFORMATION ON WHETHER A SPECIFIC VEHICLE MAY BENEFIT FROM THE INFORMATION.

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