CAMPAIGN:INTAKE MANIFOLD GASKET. Chevrolet Beretta 1992

For 1990-2009 cars

# CAMPAIGN:INTAKE MANIFOLD GASKET

#### Subject: PRODUCT CAMPAIGN 93C25 - INTAKE MANIFOLD GASKET

#### Model and Year: 1992-93 CAVALIER, CORSICA AND BERETTA W/ 2.2L ENGINES

#### To: All Chevrolet/Geo Dealers

General Motors has determined that certain 1992-93 Chevrolet Cavalier, Corsica and Beretta model vehicles equipped with 2.2L Engines (RPO LN2; VIN Code "4") may have been assembled with an intake manifold gasket (between intake manifold and the cylinder head) that will move out of position due to engine thermo cycling. This may result in rough idling, a check engine light coming on, stalling and/or hesitation on acceleration.

To prevent this condition from occurring, dealers are to replace the intake manifold gasket on involved vehicles.

#### VEHICLES INVOLVED

Involved are certain 1992-93 Chevrolet Cavalier, Corsica and Beretta model vehicles equipped with 2.2L Engines (RPO LN2) and built within the following VIN breakpoints:

PLANT YEAR MODEL PLANT CODE FROM THROUGH -------------------------------------------------------------------------- 1992 J-Car Lordstown "7" N7100001 N7325951

1993 J-Car Lordstown "7" P7100001 P7338052

1992 L-Car Wilmington "Y" NY100001 NY297283

1993 L-Car Wilmington "Y" PY100001 PY272840

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

These 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. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

#### OWNER NOTIFICATION

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

#### DEALER CAMPAIGN RESPONSIBILITY

All unsold new vehicles in dealers' possession and subject to this campaign must be held and inspected/repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your new vehicle inventory with no owner information indicated on the dealer listing, are to be contacted by the dealer, and arrangements made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such owners a copy of the owners letter accompanying this bulletin. Campaign follow-up cards should not be used for this purpose, since the owner may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

#### PARTS INFORMATION

Dealers will be preshipped intake manifold gaskets (with no delivery charge) equivalent to 35% of their involved vehicles beginning December 16, 1993.

Additional parts required to complete this campaign are to be obtained from General Motors Service Parts Operations (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).

Quantity/ Part Number Description Vehicle ----------- ----------- --------- 24574409 Lower Intake Manifold Gasket 1

#### SERVICE PROCEDURE

#### Notice: If a vehicle has been repaired for this condition and the repair order indicates that the improved gasket (P/N 24574409) has already been installed, this procedure is not required. Proceed to step 33.

1. Disconnect negative battery cable after noting radio settings.

2. Relieve fuel pressure following procedure in applicable service manual, section 6E3-C2.

3. Remove air cleaner duct assembly and top half of air cleaner.

4. Disconnect vacuum lines from fuel pressure regulator, EGR, PCV and power brake booster.

5. For vehicles equipped with automatic transaxles, position transaxle fill tube and indicator assembly aside referring to appropriate service manual, section 7A.

6. Remove throttle cable splash shield, throttle cables and throttle cable bracket. Refer to appropriate service manual, section 6C.

7. For 1993 models, disconnect secondary ignition wiring from spark plugs and relocate ignition wiring harness.

8. Route power steering lines under air inlet blower case.

9. Loosen power steering pencil brace bolt at power steering pump and remove power steering pencil brace bolt at intake manifold. Position brace aside (do not remove from vehicle).

10. For Beretta and Corsica models, position the main engine harness which runs along the front of dash towards the top of the front of dash.

For Cavaliers, position generator harness to pulley side of power steering pump.

11. Loosen fuel line retainer under intake manifold. Refer to appropriate service manual, section 6C.

12. Remove fuel line feed hose retainer from intake manifold. Refer to appropriate service manual, section 6C.

13. Disconnect both fuel lines from intake manifold. Refer to appropriate service manual, section 6C.

14. Remove lower intake manifold nuts.

15. Remove four (4) upper intake manifold studs from cylinder head.

16. Remove intake manifold assembly from cylinder head.

17. Clean and inspect intake manifold and cylinder head mating surfaces.

#### Notice: Mating surfaces must be clean and free of foreign material, grease or dirt.

Do not sand or rough up either of the mating surfaces prior to installation of new gasket.

18. Install intake manifold and gasket.

#### Notice: To prevent damage to gasket, install lower intake manifold gasket against cylinder head before installing intake manifold.

Do not use additional materials or sealants to improve gasket sealing ability.

19. Install and tighten four (4) upper intake manifold studs into cylinder head. Tighten intake manifold fasteners in sequence to specifications shown in appropriate service manual, section 6A2.

20. Connect both fuel lines to intake manifold. Refer to appropriate service manual, section 6C.

21. Install fuel feed hose retainer to intake manifold. Refer to appropriate service manual, section 6C.

22. Route fuel line under fuel line retainer and tighten retainer. Refer to appropriate service manual, section 6C.

23. Route main engine wiring harness (Beretta/Corsica) or generator harness (Cavalier) to original location. Refer to appropriate service manual, section 8A.

24. Reinstall power steering pump pencil brace as follows:

- Return power steering pump pencil brace to original location.

- Install and tighten power steering pump pencil brace to intake manifold bolt.

- Tighten power steering pump pencil brace to pump bolt.

Refer to appropriate service manual, section 3B.

25. Route power steering lines to correct position.

26. For 1993 models, route and reconnect secondary ignition wiring.

27. Reinstall throttle cable splash shield, throttle cables and throttle cable bracket. Refer to appropriate service manual, section 6C.

28. For vehicles equipped with automatic transaxles, reposition transaxle fill tube and indicator assembly. Refer to appropriate service manual, section 7A.

29. Reconnect vacuum lines from fuel pressure regulator, EGR, PCV and power brake booster.

30. Reinstall air cleaner duct assembly and top half of air cleaner.

31. Reconnect negative battery cable and reset radio settings and clock.

32. Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks. If an leaks are detected, repair as necessary.

33. Install Campaign Identification label.

#### CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label". Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner. Additional "Campaign Identification Labels" can be obtained from DAC.

Apply "Campaign Identification Label" only on a clean, dry surface.

#### CLAIM INFORMATION

Submit a Product Campaign Claim with the information indicated below:

* FAILED PARTS CC-FC LABOR LAB OTH REPAIR PERFORMED PC PART NO. ALLOW OP HRS HRS -------------------------------------------------------------------------- 1992 Model Year Vehicles - Manual Transmission - 1 24574409 ** SK-00 V8370 1.7 0.1 Install New Intake Manifold Gasket

1992 Model Year Vehicles - Auto. Transmission - 1 24574409 ** SK-00 V8371 1.8 0.1 Install New Intake Manifold Gasket

1993 Model Year Vehicles - Install 1 24574409 ** SK-00 V8372 1.8 0.1 New Intake Manifold Gasket

Vehicle Previously Repaired With Improved Gasket - - - - - SK-00 V8374 0.2 0.1 Any Model Year Vehicle - Confirmed By Repair Order

* Campaign Administrative Allowance.

** The "Parts Allowance" should be the sum total of the current GMSPO Dealer Net price plus 30 of all parts required for the repair.

Dealers will automatically receive the correct labor and material allowance based on the labor operation performed.

Refer to the Chevrolet Claims Processing Manual for details on. Product Campaign Claim Submission.

Dear Chevrolet Cavalier, Corsica or Beretta Owner:

This notice is to inform you that Chevrolet Motor Division is conducting a recall campaign that includes your vehicle.

#### REASON FOR THIS RECALL

General Motors has determined that certain 1992-93 Chevrolet Cavalier, Corsica and Beretta model vehicles equipped with 2.2L Engines have been assembled with a lower intake manifold gasket that can move out of position due to engine thermo cycling. This may result in rough idling, a check engine light coming on, stalling and/or hesitation on acceleration.

#### WHAT WE WILL DO

To correct this condition, your dealer will replace the lower intake manifold gasket on your vehicle. This service will be performed for you at no charge.

#### WHAT YOU SHOULD DO

Please contact your Chevrolet dealer as soon as possible to arrange a service date and so the dealer may order the necessary parts for the repair. Instructions for performing this service have been sent to your dealer and parts are available. You may ask your dealer if you wish to know how much time will be needed to schedule and process your vehicle.

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

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Chevrolet Motor 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.