SPECIAL POLICY: CRACKED EXHAUST MANIFOLD. Buick Skyhawk 1985

For 1990-2009 cars

# SPECIAL POLICY: CRACKED EXHAUST MANIFOLD

#### MODELS AFFECTED: 1985-86 SKYHAWK WITH 2.0L (LQ5) ENGINE (VIN CODE P) AND CALIFORNIA EMISSIONS (NB2)

General Motors has determined that some 1985-86 Skyhawks built with 2.0L 4-cylinder LQ5 engine and California emissions may experience a cracked exhaust manifold which could result in excessive engine noise.

#### VEHICLES INVOLVED

Involved are all 1985-86 Skyhawks built with 2.0L LQ5 engine (VIN Code P) and California emissions (RPO NB2) within the following VIN's:

ENGINE YEAR SERIES CODE PLANT FROM THROUGH & INCLUDING ---- ------ ---- ----- ---- ------------------- 1985 Skyhawk P Leeds FK400021 FK481264 1986 Skyhawk P Leeds GK401172 GK491399

#### NOTICE: This policy applies to these vehicles produced with 2.0L RPO LQ5 4-cylinder engines with California Emissions RPO NB2, regardless of current state residence of the owner.

#### SPECIAL POLICY ADJUSTMENT

This special policy covers the condition described above for those vehicles over 50,000 miles. A one time free inspection and, if necessary, free replacement of a cracked exhaust manifold (regardless of time/mileage) for three (3) months (90 days) from date of the owner letter, is provided for by the "Special Policy". Correction will consist of the installation of a new exhaust manifold and/or exhaust pipe seal, at no charge to the owner.

#### OWNER NOTIFICATION

Owners will be notified of this special policy on their vehicles by Buick Motor Division (see copy of owner letter included with this bulletin).

#### REIMBURSEMENT

Customer claims for reimbursement on previously paid repairs to correct an exhaust manifold leak, are to be submitted within 3 months (90 days) from the date of the owner letter according to the instructions included in this bulletin. Owners must submit original documentation that reasonably confirms the amount of unreimbursed repair expenses, a description of the repair, the date of the repair, and the person or entity performing the repair.

#### PARTS INFORMATION

PART NUMBER DESCRIPTION QUANTITY/VEHICLE ----------- ------------ ---------------- 14086036 Exhaust Manifold 1 14083542 Exhaust Manifold Seal 1

#### SERVICE PROCEDURE

#### Inspection

1. BLOCK THE WHEELS AND APPLY THE PARKING BRAKE. Lift the hood and listen for an audible exhaust noise while increasing the engine speed in park.

2. A check for a leaking exhaust seal (donut) should be performed prior to exhaust manifold replacement. If the seal leaks, replace it and rerun the inspection (WITH THE WHEELS BLOCKED AND PARKING BRAKE APPLIED) before exhaust manifold replacement.

Exhaust Manifold Replacement

#### IMPORTANT: The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector could affect proper operation of the sensor.

Take care when handling the oxygen sensor. The in-line electrical connector and louvered end must be kept free of grease, dirt or other contaminants. Also, avoid using cleaning solvents of any type. Do not drop or roughly handle the sensor.

1. Disconnect battery ground cable from battery.

2. Disconnect oxygen sensor electrical connector.

3. Carefully remove oxygen sensor from exhaust manifold.

4. Remove engine oil dipstick.

5. Remove air cleaner hot air duct hose.

6. Remove the screw retaining the dipstick tube bracket (and A/C suction line bracket, if so equipped).

7. Loosen the generator support to generator bolt, remove the two generator bracket to generator bolts, being careful not to lose the spacer used at the left generator to bracket bolt.

8. Remove the generator belt from the generator pulley, rotate the generator upward and install the left generator to bracket bolt loosely so that it acts as a stop against the bracket preventing the generator from rotating too far downward.

9. Raise the vehicle.

10. Disconnect the exhaust pipe from the exhaust manifold.

11. Lower the vehicle.

12. Remove exhaust manifold to cylinder head bolts, lift the exhaust manifold off the exhaust pipe flange and remove the exhaust manifold from the cylinder head.

13. Clean mating surfaces, bolts and bolt holes.

14. Reverse the manifold removal procedure and torque the fasteners to the following specifications:

- Exhaust Manifold Bolt: 46-60 N.m (34-44 lb. ft.) - Generator Bracket to Head: 40-60 N.m (29-44 lb. ft.) - Generator Brace: 40-60 N.m (29-44 lb. ft.) - Generator Pivot Bolt: 40-60 N.m (29-44 lb. ft.) - Generator Adjustment Bolt: 20-27 N.m (15-20 lb. ft.)

#### IMPORTANT: New or service sensors will alread have a special anti-seize compound on the threads. If a sensor is removed from an engine, and if it is reinstalled, the threads must have anti-seize compound applied before reinstallation.

15. Coat threads of oxygen sensor with anti-seize compound, part number 5613695 or equivalent, if necessary.

16. Reinstall sensor in manifold, torque to 41 N.m (30 lb. ft.).

17. Reconnect sensor electrical connector.

18. Connect battery ground cable to the battery.

WARRANTY CLAIM INFORMATION

When performing the repairs outlined in the Service Procedure of this bulletin, submit a warranty claim for credit as indicated below for those vehicles beyond 5 years/50,000 miles. Use the applicable warranty labor operation number for those vehicles within 5 years/50,000 miles.

FAILED SUBLET PART PART PARTS FAILURE LABOR LABOR DEALER OPER COUNT NUMBER ALLOW CODE OP NO HOURS MTL TWG ---- ----- ------ ------ ---- ------- ----- ------- Inspect for leak -- -- -- 95 T1518 .2 -- Inspect for leak and replace seal only 1 14093542 * 95 T1527 .3 -- Install new manifold and seal 2 14086036 * 95 T1519 1.3 -- Reimbursement for previous repair T1520 See Instructions For Reimbursement * List current dealer price of parts, plus 30%

REQUEST FOR REIMBURSEMENT INSTRUCTIONS

1. Customer presents dealer with original paid receipts covering repairs to replace exhaust manifold and/or seal.

2. Dealer completed a repair order (R.O.) showing:

- Repair order date. - Vehicle Identification Number. - Current mileage. - Owner's address. - Attaches original owner's or dealer's paid invoices/receipts covering repair within the Special Policy 90 day date on owner letter guideline. - Use Labor Operation Number T1520 and Failure Code 95. - Enters total amount of reimbursement based on 100% of OWNER'S EXPENSE related to covered steering repair.

3. Owner signs the repair order as acknowledgement of requested reimbursement amount.

4. Owner is given a copy of repair order.

5. Dealer assigns a Warranty Management System (WMS) authorization code to the claim and enters it on the WMS Authorization Log.

6. The dealer submits a claim to Buick for processing.

7. Dealer issues the owner a reimbursement check for the approved amount. The check number must be entered on the repair order and a copy of the check must be attached to original paid invoices/receipts.

8. All supporting documentation must be available for review by Buick personnel as needed.

#### NOTICE: Refer to Buick Service Policies and Procedures Manual, Section 1.6.1 1 for specific procedures for Customer Reimbursement verification.

In the event the Dealer Service Manager and the owner cannot reach agreement on amount eligible for reimbursement after review of invoices/receipts, the Zone/Branch should be contacted for determination of covered expenses. In such cases, an explanation should be included on the R.O.

Dear Buick Owner:

As the owner of a 1985-86 Buick Skyhawk equipped with a 2.0L engine, your continued satisfaction with our product is of utmost concern to us. Your vehicle was provided with a new vehicle warranty as well as an emission warranty which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you experience problems with your vehicle.

This letter is intended to make you aware that some vehicles have experienced a cracked exhaust manifold. The cost to repair this condition may be as much as $200.00. The affected part is listed in the California Emission Warranty Parts List and is covered under the California emissions warranty for 5 years/50,000 miles, whichever occurs first.

Leakage from the exhaust manifold may be detected by listening for excessive engine noise during acceleration. You need to return to your servicing Buick dealer for a free inspection only if you notice this problem. If the above mentioned condition exists and your vehicle is within the 5 year/50,000 mile California Emission Warranty, it will be repaired free of charge. If you previously paid for this repair, you should contact your Buick dealer within 3 months (90 days) from the date of this letter to request reimbursement. Vehicles beyond the 5 year/50,000 mile period will be inspected and, if required, repaired free of charge for a period of three months (90 days) from the date of this letter.

If the above condition exists, please contact your Buick dealer as soon as possible to arrange a service date. Instructions for making this correction have been sent to your dealer. The labor time necessary to perform this service (inspection/correction) is approximately one hour and 20 minutes. Please ask your dealer if you wish to know how much additional time will be needed to schedule and process your vehicle.

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, and indicates to the dealer the 90 day period. 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.