For 1990-2009 cars

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

#### SUBJECT: QUAD 4 IGNITION COIL

#### MODELS AFFECTED: CERTAIN 1988-90 SKYLARK WITH 2.3L ENGINE (VIN CODE D)

#### CONDITION

General Motors has determined that some 1988-90 Buick Skylark models equipped with 2.3L (VIN Code D) engine (option LD2) 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 "no start" condition when the coil fails completely.

#### DEALER ACTION

To correct this condition, dealers are to inspect the ignition coils, and if necessary, replace coils as instructed in the Service Procedure section of this bulletin.

#### VEHICLES INVOLVED

Certain 1988-90 Buick Skylark models equipped with 2.3L (VIN Code D) engine within the following breakpoints:

THROUGH AND YEAR PLANT FROM INCLUDING ---- ---------- -------- ---------- 1988 Lansing JM000002 JM054799 1989 Lansing KM000001 KM061525 1990 Lansing LM000006 LM066523

#### NOTICE: VEHICLES LISTED IN BUICK'S RECORDS AS PREVIOUSLY REPAIRED UNDER LABOR OPERATION T4676 WERE DELETED FROM THIS CAMPAIGN.

All vehicles listed on the dealer printout will require inspection, and as necessary, correction. Other suspect vehicles should be checked for campaign involvement by utilizing the Vehicle Information Service System (V.I.S.S.) for verification.

DEALER CAMPAIGN RESPONSIBILITY

If there is evidence of intentional disablement of the emission system, the dealer is to notify the vehicle owner of this condition and ask if he/she wants the system restored. Restoration cost is the responsibility of the owner.

Dealers are to service all vehicles involved in this campaign at no charge to the owner, regardless of mileage, age of vehicle, or ownership. Whenever a vehicle subject to this campaign is taken into your new or used car inventory, dealers are to take the steps necessary to be sure the campaign correction has been made before reselling 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.

In addition, dealers are to perform the campaign on all affected vehicles as they are brought in for any kind of service.

#### DEALER MATERIAL

If your dealership has vehicles involved in this campaign, you will receive the following items:

- Listing of all vehicles involved in this campaign shipped to your dealership.

- One (1) Campaign Identification Label per vehicle involved.

Involved vehicles have been identified by Vehicle Identification Number computer listings. Computer listings contain the complete identification number, owner number and address data, and are furnished to the involved dealers with the campaign bulletin. Owner name and address data will enable dealers to follow-up with owners involved in this campaign.

These computer listings may contain owner names and addresses obtained from State Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

#### OWNER NOTIFICATION

Owners of vehicles involved in this campaign will be notified by Buick Motor Division (see copy of owner letter included with this bulletin).

#### CHANGE OF OWNER INFORMATION

Dealers are to use the Dealer Communication System (DCS) to provide Buick Motor Division with subsequent Buick owner information. By reporting a change of owner name or address of a vehicle in campaign status over the DCS, the need to send a CVAR form for that vehicle is eliminated. Terminal input instructions are covered in the DCS Manual under Section 9, Page 9-J01A and B.

#### PARTS INFORMATION

Parts required to complete this campaign are to be obtained from General Motors Service Parts Operation (GMSPO). To ensure these parts will be obtained as soon as possible, they should be ordered from GMSPO on a C.I.O. order, with NO special instruction code, but on an advise code (2).

DESCRIPTION PART NUMBER QUANTITY/VEHICLE ----------------------- ----------- ----------------- Coil Kit (Quad 4 Engine) 10457062 1 (as required)

It is expected that almost 100% coil replacement will be performed on involved vehicles, hence kits should be ordered based on the number of vehicles listed on the VIN printout sent to dealers with involved vehicles.

SERVICE PROCEDURE

1. Raise hood.

2. With the ignition in the "off" position, disconnect the negative battery cable from the battery. A memory retention device, such as Kent-Moore tool, KS295A, may be used to retain 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, turn 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 color 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" coils(s), the contact(s), and the seal(s) from the cover (See Figure 1, Item 6 and in View A, Items 13 & 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 advise customer that the battery was disconnected (not required if a memory retention tool was used) and the radio and clock may need resetting.

17. Install a Campaign Identification Label.

#### CAMPAIGN IDENTIFICATION LABEL

Each label provides a space to include the CAMPAIGN NUMBER, the five (5) digit dealer code of the dealer performing the campaign service, and the date vehicle was campaigned. This information may be inserted with a typewriter or ballpoint pen. When installing label, clean the surface of the radiator support tie bar and apply the campaign label where it is readily visible.

#### DISPOSITION OF PARTS

Replaced parts must be held for disposition by Buick Zone or Branch contact personnel. Parts must have a claim tag attached showing the repair order and the VIN of the vehicle from which they are removed.

#### WARRANTY INFORMATION

FAILED OTHER SUBLET PART PART PARTS FAILURE LABOR LABOR LABOR DEALER OPER COUNT NUMBER ALLOW CODE OP NO HOURS HOURS MTL TWG ---- ----- ------ ----- ------ ------ ----- ----- ------- o Inspect Ignition Coils only -- -- -- 96 V6510 0.3 0.1* --

o Inspect and Replace Ignition Coils 1 10457062 ** 96 V6511 0.3 0.1* --

* 0.1 hour administration

** List current dealer price of part, plus 30%

Dear Buick Owner:

This notice is to inform you that Buick Motor Division is conducting an emission recall that includes your vehicle.

REASON FOR RECALL

General Motors has determined that some 1988-90 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.

WHAT WE WILL DO

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

WHAT YOU SHOULD DO

Please contact your Buick dealer to arrange a service date. Instructions have been sent to your Buick dealer. It is estimated that parts will be available to your dealer March 27, 1991. Please ask your dealer if you desire an estimate of the total time needed to schedule and process your vehicle. Included in this time would be about twenty (20) minutes for a technician to inspect the ignition coils, and if necessary, replace them.

Please contact your dealer for an appointment to bring in your vehicle even if you believe it was previously repaired for a misfire, rough idle or "no start" condition.

Your Buick dealer is best equipped to obtain parts and provide service to ensure your vehicle is corrected as promptly as possible. However, if you take your vehicle to your dealer on the agreed service date, and he does not remedy this condition on that date or within five (5) days, we recommend that you contact the Buick Customer Assistance Center, Flint Home Office by calling 1-800-521-7300. The Customer Assistance Center will assist you and the dealer in getting your vehicle serviced.

The enclosed Owner Reply Card identifies your vehicle. Presentation of this card to your dealer will assist in making the correction in the shortest possible time. If you have sold or traded your vehicle, please let us know by completing the postage-paid owner reply card and returning it to us.

To ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection test if the recall work is not accomplished.

Should your dealer find that your emission system has been intentionally disabled, you will be asked if you wish the system to be restored so that it will function as designed. The cost of such restoration will be your responsibility.

We are sorry for this inconvenience; however, we took this action to assure that your vehicle meets applicable government emission requirements and 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.