For 1990-2009 cars

# CAMPAIGN: QUAD 4 IGNITION COIL INSPECT COIL CASE FOR CRACKS

#### Models: 1990 Chevrolet Beretta GTZ 1988-1989-1990 Pontiac Grand Am 1990 Pontiac Grand Prix 1988-1989-1990 Oldsmobile Cutlass Calais 1990 Oldsmobile Cutlass Supreme 1988-1989-1990 Buick Skylark

General Motors of Canada Limited has determined that certain 1990 Chevrolet Beretta GTZ, 1988- 1989-1990 Pontiac Grand Am, 1990 Pontiac Grand Prix, 1988-1989-1990 Oldsmobile Cutlass Calais, 1990 Oldsmobile Cutlass Supreme and 1988-1989-1990 Buick Skylark models equipped with 2.3L (VIN Code D or A) engines (Options LD2 or LGO) may develop cracks in the case of the I.D.I. (Integrated Direct Ignition) coil at the high voltage terminals. As the cracks grow, external arcing occurs between terminals and/or terminal to coil frame resulting in intermittent misfire, rough idle, and ultimately a "no start" condition when the coil fails completely. This may result in a non-compliance with CMVSS 1103 - Exhaust Emissions.

Dealers will inspect the ignition coils, and, if necessary, replace coils as instructed in the SERVICE PROCEDURE section of this bulletin.

#### VEHICLES INVOLVED:

Involved are certain 1990 Chevrolet Beretta GTZ, 1988-1989-1990 Pontiac Grand Am, 1990 Pontiac Grand Prix, 1988-1989-1990 Oldsmobile Cutlass Calais, 1990 Oldsmobile Cutlass Supreme and 1988-1989-1990 Buick Skylark models equipped with 2.3L (VIN Code D or A) engines (Options LD2 or LGO) within the breakpoints listed below:

Carline Model RPO/VIN 1988 1989 1990 --------- ---------- ------- ----- ---- ------------- Chevrolet Beretta GTZ LGO/A SOP - LY227075

Pontiac Grand Am LD2/D All All SOP - LC355447 Grand Am LGO/A SOP - LC354776 Grand Prix LD2/D SOP - LF297771

Oldsmobile Cutlass Calais LD2/D All All SOP - LM767172 Cutlass Calais LGO/A SOP - LM766824 Cutlass Supreme LD2/D SOP - LD400016 Cutlass Supreme LGO/A SOP - LD401388

Buick Skylark LD2/D All All SOP - LM066530

All affected vehicles have been identified by the VIN listing provided to involved dealers with this bulletin. Any dealer not receiving a listing was not shipped any of the affected vehicles.

#### DEALER CAMPAIGN RESPONSIBILITY:

Dealers are to perform this campaign on all involved vehicles at no charge to owners, regardless of kilometres traveled, age of vehicle, or ownership, 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, you are to ensure the campaign correction has been made before selling or releasing the vehicle.

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.

#### CAMPAIGN PROCEDURE:

Refer to Section 4 of the Service Policies and Procedures Manual for the detailed procedure on handling Product Campaigns. Dealers are requested to complete the campaign on all transfers as soon as possible.

#### OWNER NOTIFICATION:

All owners of record at the time of campaign release are shown on the attached computer listing and have been notified by first class mail from General Motors. The listings provided are for campaign activity only and should not be used for any other purpose.

#### PARTS INFORMATION:

Parts required to complete this campaign should be ordered through regular channels, as follows:

Part Number Description Quantity/Vehicle ----------- ----------- ---------------- 10457062 Coil Kit 1 Kit

The Coil Kit contains:

10472748 IDI Ignition Coil 2

Credit for the campaign work performed will be paid upon receipt of a properly completed campaign claim card or DCS transmission in accordance with the following:

Repair Code Description Time Allowance ----------- ------------------------- -------------- 1A Inspect Ignition Coils Only .4

2A Inspect and Replace Ignition Coil(s) .4

3A Inspect Owner's Prior Repair Orders, and Confirm 3 that two "Yellow Tab" Coils had been Installed (Two P/N 10472748 Coils or Both Coils from Kit P/N 10457062)

T4680 Owner Reimbursement for Prior Repair

Time allowance includes 0.1 hour for dealer administrative detail associated with this campaign. Parts credit will be based on dealer net plus 30% to cover parts handling.

#### OWNER REIMBURSEMENT

Customers may request reimbursement for prior replacement of the ignition coil(s) due to misfire, rough idle, or a "no start" condition. 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 who performed the repair to receive reimbursement.

#### NOTE: When a customer requests reimbursement, and the vehicle is still available, dealers are to inspect and, if necessary, replace ignition coils as called for in the SERVICE PROCEDURE of this bulletin. If owner's documentation indicates that both coils were replaced using coils from Kit P/N 10457062 (or two P/N 10472748 coils), then Repair Code 3A may be applied for and it is not necessary to physically inspect the involved vehicle. Until the involved vehicle is confirmed to have the new coils installed (by inspection of the vehicle or the repair order, and any necessary replacement of coils performed), the campaign must remain open regardless of any reimbursement.

#### SERVICE PROCEDURE:

1. Raise and support the hood.

2. Write down the owner's preset radio stations and such other memory functions that can be recorded and reset later; then, with the ignition in the "off" position, disconnect the negative battery cable from the battery. If a memory retention device, such as a Kent-Moore tool KS295A, is used, it is not necessary to record memory functions.

3. Do NOT disconnect the 11 pin IDI harness connector.

4. Remove the four bolts, ignition system assembly to cam housing.

5. Remove the ignition system assembly from the engine, tum it upside down and lay it on the engine using two bolts as "locator pins" through the cover into the cam housing on the "rear side" of the engine to hold the ignition system assembly in place.

#### NOTICE: If boots adhere to spark plugs, use Tool J-36011 to remove by first twisting and then pulling upward on retainers. Reinstall boots and retainers on IDI housing secondary terminals, making sure that the spark plug connectors (Item 9 in Figure 1) are in place. Boots and retainers must be in place on IDI housing secondary terminals prior to ignition system assembly installation or ignition system damage may result.

6. Remove the four housing to cover screws (Item 4 in Figure 1) and remove the ignition coil housing (Item 7) from the cover (Item 1).

7. Remove the coil harness connectors (Item 5) from the coils.

8. Refer to Figure 2, and inspect the two ignition coils for colour of electrical tab. Ignition Coils with black electrical tabs are to be replaced with new coils having yellow electrical tabs (from Kit P/N 10457062). Coils with yellow electrical tabs do not require replacement. It should be rare to find a campaign vehicle in which one or both coils already have yellow tabs.

9. If necessary to replace one or both coils, remove the "black tab" coil(s), the contact(s), and the seal(s) from the cover (See Figure 1, Item 6 in View A, Items 13 and 14).

10. Reinstall seal(s) (Item 14 in Figure 1) to the housing.

11. Reinstall contact(s) (Item 13) to the housing (use petroleum jelly to retain).

12. Install new "yellow tab" coil(s) to the cover, as required. Install coil harness connectors to both coils.

13. Reinstall the housing (Item 7 in Figure 1) to the cover (Item 1) with four screws (Item 4); torque screws to 4 N.m (35 lb. in.).

14. Install the ignition system assembly to the engine while carefully aligning boots to the spark plug terminals.

15. Coat the four bolts, ignition system assembly to cam housing, with P/N 1052080 sealer (or equivalent). Install the bolts through the cover to the cam housing and torque to 20 N.m (15 lb. ft.).

#### NOTICE: If the above bolts are not coated with sealer prior to reinstallation, future removal of the bolts may strip the threads in the aluminum of the cam housings.

16. Reconnect the negative battery cable. In the interest of customer satisfaction, please reset (to the extent possible) all devices that lost their memory after the battery was disconnected (not required if a memory retention tool was used).

17. Install a Campaign Identification Label.

#### INSTALLATION OF CAMPAIGN IDENTIFICATION LABEL:

Clean surface of radiator upper mounting panel and apply a Campaign Identification Label. Make sure the correct campaign number is inserted on the label. This will indicate that the campaign has been completed.

Dear General Motors Customer:

General Motors of Canada Limited has determined that certain 1990 Chevrolet Beretta GTZ, 1988- 1989-1990 Pontiac Grand Am, 1990 Pontiac Grand Prix, 1988-1989-1990 Oldsmobile Cutlass Calais, 1990 Oldsmobile Cutlass Supreme and 1988-1989-1990 Buick Skylark models equipped with 2.3L engines may develop cracks in the case of the Ignition coil at the high voltage terminals. As the cracks grow, external arcing occurs between terminals and/or terminal to coil frame resulting in intermittent misfire, rough idle, and ultimately a "no start" condition when the coil fails completely. This may result in a non-compliance with CMVSS 1103 - Exhaust Emissions.

To prevent this condition from occurring on your vehicle, your General Motors dealer will inspect the ignition coils, and, if necessary, replace them at no charge to you.

Please contact your GM dealer as soon as possible to arrange a service date.

This letter identifies your vehicle. Presentation of this letter to your dealer will assist their Service personnel in completing the necessary correction to your vehicle in the shortest possible time.

Further assistance, if required, may be obtained from our Customer Assistance Centre, toll free, by calling 1-800-263-3777, or if you live in Quebec, 1-800-263-7854.

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.